TOHATSU BFT 75A, BFT 90A Owner's Manual
OWNER’S MANUAL
BFT 75A
90A
The engine exhaust from this
product contains chemicals
known to the State of California to
cause cancer, birth defects, or
other reproductive harm.
Keep this Owner’s Manual handy, so you can refer to it at any time. This Owner’s
Manual is considered a permanent part of the outboard motor and should remain with
the outboard motor if resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Honda Motor Co., Ltd. reserves the right, however, to discontinue or change
specifications or design at any time without notice and without incurring any obligation whatever. No part of this publication may be reproduced without written permission.
INTRODUCTION
Congratulations on your selection of
a TOHATSU outboard motor. We are
certain you will be pleased with your
purchase of one of the finest
outboard motors on the market.
We want to help you get the best
results from your new outboard
motor and to operate it safely. This
manual contains information on how
to do that; please read it carefully.
As you read this manual you will
find information preceded by a
symbol. That information
is intended to help you avoid damage
to your outboard motor, other
property, or the environment.
We suggest you read the warranty
policy to fully understand its
coverage and your responsibilities of
ownership.
When your outboard motor needs
scheduled maintenance, keep in mind
that your TOHATSU dealer is
specially trained in servicing
TOHATSU outboard motors. Your
TOHATSU dealer is dedicated to
your satisfaction and will be pleased
to answer your questions and
concerns.
Best Wishes,
Tohatsu Corporation
1
INTRODUCTION
A FEW WORDS ABOUT
SAFETY
Your safety and the safety of others
are very important. And using this
outboard motor safely is an important
responsibility.
To help you make informed
decisions about safety, we have
provided operating procedures and
other information on labels and in
this manual. This information alerts
you to potential hazards that could
hurt you or others.
Of course, it is not practical or
possible to warn you about all the
hazards associated with operating or
maintaining an outboard motor. You
must use your own good judgment.
You will find important safety information in a variety of forms, including:
• Safety Labels — on the outboard motor.
• Safety Messages — preceded by a safety alert symbol and one of
three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY
HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY
HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow
instructions.
• Safety Headings — such as IMPORTANT SAFETY INFORMATION.
• Safety Section — such as OUTBOARD MOTOR SAFETY.
• Instructions — how to use this outboard motor correctly and safely.
This entire book is filled with important safety information — please read it
carefully.
2
CONTENTS
OUTBOARD MOTOR SAFETY .................................... 7
IMPORTANT SAFETY INFORMATION................. 7
SAFETY LABEL LOCATION................................... 9
CONTROLS AND FEATURES .................................... 11
CONTROL AND FEATURE IDENTIFICATION
CODES................................................................... 11
COMPONENT AND CONTROL LOCATIONS..... 12
CONTROLS.............................................................. 18
Side-Mount Type ................................................. 18
Ignition Switch................................................ 18
Emergency Stop Switch Clip and Emergency
Stop Switch .................................................. 18
Gearshift/Throttle Control Lever .................... 19
Fast Idle Lever ................................................ 20
Panel-Mount Type................................................ 21
Ignition Switch................................................ 21
Emergency Stop Switch Clip and Emergency
Stop Switch .................................................. 22
Gearshift/Throttle Control Lever .................... 23
Fast Idle Button............................................... 24
Top-Mount Type .................................................. 25
Ignition Switch................................................ 25
Emergency Stop Switch Clip and Emergency
Stop Switch .................................................. 25
Gearshift/Throttle Control Lever .................... 26
Fast Idle Button............................................... 28
TRL (Trolling) Control Switch
(optional equipment)...........................................29
Power Trim/Tilt Switch ........................................30
Power Tilt Switch .................................................31
Manual Relief Valve.............................................31
Tilt Lock Lever.....................................................32
Engine Cover Latch (front/rear) ...........................32
Trim Tab ...............................................................32
INSTRUMENTS .......................................................33
Trim Meter (optional equipment) .........................33
Tachometer (optional equipment) ........................33
Fuel Gauge (optional equipment) .........................33
3
CONTENTS
INDICATORS........................................................... 34
Alternator (ACG) Indicator.................................. 34
Malfunction Indicator........................................... 34
Oil Pressure Indicator........................................... 35
Overheat Indicator................................................ 35
Cooling System Indicator..................................... 36
OTHER FEATURES ................................................ 37
Water Separator Buzzer ....................................... 37
Overrev Limiter.................................................... 37
Portable Fuel Tank (optional equipment) ............ 37
Fuel Filler Cap Vent Knob................................... 38
Fuel Priming Bulb................................................ 38
Anodes.................................................................. 39
NMEA Interface Coupler..................................... 40
Operating Hour Notification System ................... 40
BEFORE OPERATION ................................................. 43
ARE YOU READY TO GET UNDERWAY? ......... 43
IS YOUR OUTBOARD MOTOR
READY TO GO? ................................................... 43
OPERATION..................................................................45
SAFE OPERATING PRECAUTIONS .....................45
BREAK-IN PROCEDURE........................................45
PORTABLE FUEL TANK (optional equipment)..... 46
FUEL HOSE CONNECTIONS.................................46
FUEL PRIMING........................................................48
INFREQUENT OR OCCASIONAL USE ................48
STARTING THE ENGINE .......................................49
Side-Mount Type..................................................49
Panel-Mount Type ................................................52
Top-Mount Type...................................................54
EMERGENCY STARTING......................................57
STOPPING THE ENGINE........................................60
Emergency Engine Stopping ................................60
Normal Engine Stopping ......................................61
GEARSHIFT AND THROTTLE OPERATION ......63
STEERING ................................................................64
CRUISING.................................................................65
SHALLOW WATER OPERATION.........................68
MOORING, BEACHING, LAUNCHING................69
MULTIPLE OUTBOARD MOTORS.......................70
4
CONTENTS
SERVICING YOUR OUTBOARD MOTOR................ 71
THE IMPORTANCE OF MAINTENANCE............ 71
MAINTENANCE SAFETY...................................... 72
TOOL KIT and OWNER’S MANUAL .................... 73
EMERGENCY STARTER ROPE ............................ 73
MAINTENANCE SCHEDULE................................ 74
TRIM TAB ADJUSTMENT..................................... 76
MANUAL RELIEF VALVE .................................... 77
ENGINE COVER REMOVAL AND
INSTALLATION................................................. 77
Engine Oil Level Check ............................................ 78
Engine Oil Change .................................................... 80
Oil Filter Change....................................................... 81
Engine Oil Recommendations ................................... 82
Spark Plug Service .................................................... 83
Lubrication Points ..................................................... 86
REFUELING............................................................. 88
FUEL RECOMMENDATIONS ............................... 90
Water Separator Inspection and Service ................... 91
Fuel Filter Inspection and Replacement.................... 94
Portable Fuel Tank and Tank Filter Cleaning
(optional equipment) .............................................. 97
Anode Replacement .................................................. 98
Propeller Replacement .............................................. 98
Inspect After Operating ........................................... 100
CLEANING AND FLUSHING....................................101
Cleaning and Flushing .................................101
STORAGE ....................................................................103
Fuel .....................................................................103
Engine Oil...........................................................105
HOISTING THE OUTBOARD MOTOR ...............105
STORAGE PRECAUTIONS ..................................105
REMOVAL FROM STORAGE..............................106
TRANSPORTING ........................................................107
WITH OUTBOARD MOTOR
INSTALLED ON BOAT......................................107
WITH OUTBOARD MOTOR
REMOVED FROM BOAT ..................................107
TAKING CARE OF UNEXPECTED PROBLEMS ....108
ENGINE WILL NOT START.................................108
HARD STARTING OR STALLS AFTER
STARTING...........................................................111
ENGINE OVERHEATS..........................................112
FUSES .....................................................................113
Electric Starter Will Not Operate .......................113
Battery Will Not Charge.....................................113
Fuse Replacement...............................................113
5
CONTENTS
OIL PRESSURE INDICATOR TURNS OFF AND
ENGINE SPEED IS LIMITED............................ 115
OVERHEAT INDICATOR COMES ON AND
ENGINE SPEED IS LIMITED............................ 116
WATER SEPARATOR BUZZER SOUNDS......... 117
SUBMERGED OUTBOARD MOTOR.................. 118
TECHNICAL INFORMATION .................................. 120
Serial Number Locations.................................... 120
Battery ................................................................ 121
Emission Control System Information............... 121
Star Label ........................................................... 124
Specifications ..................................................... 126
CONSUMER INFORMATION................................... 129
Emission Control System Warranty................... 129
INDEX.......................................................................... 134
6
OUTBOARD MOTOR SAFETY
IMPORTANT SAFETY
INFORMATION
The TOHATSU BFT75A and
BFT90A outboard motors are
designed for use with boats that have
a suitable manufacturer’s power
recommendation. Other uses can
result in injury to the operator or
damage to the outboard motor and
other property.
Most injuries or property damage can
be prevented if you follow all
instructions in this manual and on the
outboard motor. The most common
hazards are discussed in this chapter,
along with the best way to protect
yourself and others.
Operator Responsibility
• It is the operator’s responsibility to provide the necessary safeguards to protect people and property. Know how to stop the engine quickly in case of emergency. Understand the use of all controls.
• Stop the engine immediately if anyone falls overboard, and do not run the engine while the boat is near anyone in the water.
• Always stop the engine if you must leave the controls for any reason.
• Attach the emergency stop switch lanyard securely to the operator.
• Always wear a PFD (Personal Flotation Device) while on the boat.
• Familiarize yourself with all laws and regulations relating to boating and the use of outboard motors.
• Be sure that anyone who operates the outboard motor receives proper instruction.
• Be sure the outboard motor is properly mounted on the boat.
• Do not remove the engine cover while the engine is running.
7
OUTBOARD MOTOR SAFETY
Refuel With Care
• Gasoline is extremely flammable,
and gasoline vapor can explode.
Refuel outdoors, in a wellventilated area, with the engine
stopped. Never smoke near
gasoline, and keep other flames and
sparks away.
• Refuel carefully to avoid spilling fuel. Avoid overfilling the fuel tank.
• After refueling, tighten the filler cap securely. If any fuel is spilled, make sure the area is dry before starting the engine.
Carbon Monoxide Hazard
Exhaust contains poisonous carbon
monoxide, a colorless, odorless gas.
Breathing carbon monoxide can
cause loss of consciousness and may
lead to death.
If you run the engine in an area that is
confined, or even partly enclosed, the
air you breathe could contain a
dangerous amount of exhaust gas.
Never run your outboard inside a
garage or other enclosure.
8
SAFETY LABEL LOCATION
OUTBOARD MOTOR SAFETY
The labels shown here contain important safety information. Please read them carefully. These labels are considered
permanent parts of your outboard motor. If a label comes off or becomes hard to read, contact an authorized TOHATSU
dealer for a replacement.
9
OUTBOARD MOTOR SAFETY
PORTABLE FUEL TANK
(optional equipment)
FUEL CAUTION
10
CONTROLS AND FEATURES
TYPE CODE (example)
L
R T A
Destination: A= American
Tilt System: T= Power Trim/Tilt
Control System: R= Remote Control
Transom Height (Shaft Length): L= 21.1 in (537 mm), X= 26.1 in (664 mm)
CONTROL AND FEATURE IDENTIFICATION CODES
Model BFT75A BFT90A
Typ e LRTA LRTA XRTA
Transo m Height
(Shaft Length)
Tiller Handle * * *
Remote Control * * *
Power Trim/Tilt
Tachometer * * *
Trim Meter * * *
TRL (Trolling) Control Switch * * *
* Optional equipment
Refer to this chart for an explanation of the Type Codes used in this manual to identify control and feature applications.
21.1 in (537 mm)
26.1 in (664 mm)
11
CONTROLS AND FEATURES
ENGINE COVER
LATCH (front)
STERN
BRACKET
MANUAL
RELIEF VALVE
ANODE
PROPELLER
(optional equipment)
EXHAUST PORT/WATER
OUTLET PORT
TRIM TAB
ANODE
(each side)
COOLING SYSTEM
INDICATOR
IDLE PORT
ENGINE COVER
LATCH (rear)
ENGINE COVER
OIL LEVEL DIPSTICK
OIL FILLER CAP
SPARK PLUG
(under ignition coil)
POWER TILT
SWITCH
FLUSH PORT
CONNECTOR
ENGINE OIL
DRAIN BOLT
ANTIVENTILATION
PLATE
GEAR OIL DRAIN SCREW
GEAR OIL
LEVEL SCREW
PRODUCT
IDENTIFICATION
NUMBER
TILT LOCK
LEVER
COOLING WATER
INTAKE PORT
(each side)
NMEA INTERFACE
COUPLER
COMPONENT AND CONTROL LOCATIONS
12
Remote Controls (optional equipment)
(SIDE-MOUNT REMOTE CONTROL)
GEARSHIFT/THROTTLE
CONTROL LEVER
POWER TRIM/TILT
SWITCH
SPARE EMERGENCY
STOP SWITCH CLIP
CONTROL LEVER
FRICTION ADJUSTER
EMERGENCY STOP
SWITCH LANYARD
EMERGENCY STOP
SWITCH CLIP
EMERGENCY STOP
SWITCH
IGNITION SWITCH
KEY
IGNITION SWITCH
BUZZER
(inside)
FAST IDLE LEVER
INDICATORS
(Oil pressure, Overheat,
Alternator, Malfunction)
NEUTRAL RELEASE LEVER
CONTROLS AND FEATURES
13
CONTROLS AND FEATURES
(PANEL-MOUNT REMOTE CONTROL)
CONTROL PANEL (for PANEL-MOUNT type)
GEARSHIFT/THROTTLE
CONTROL LEVER
POWER TRIM/TILT
SWITCH
NEUTRAL RELEASE
LEVER
FAST IDLE BUTTON
BUZZER
IGNITION
SWITCH
EMERGENCY STOP
SWITCH CLIP
EMERGENCY STOP
SWITCH LANYARD
EMERGENCY
STOP SWITCH
INDICATORS
(Oil pressure, Overheat,
Alternator, Malfunction)
14
CONTROLS AND FEATURES
(SINGLE TOP-MOUNT REMOTE CONTROL)
CONTROL PANEL
(for TOP-MOUNT SINGLE type)
(DUAL TOP-MOUNT REMOTE CONTROL)
(for TOP-MOUNT DUAL type)
GEARSHIFT/THROTTLE
CONTROL LEVER
POWER
TRIM/TILT
SWITCH
FAST IDLE
BUTTON
BUZZER
IGNITION
SWITCH
EMERGENCY STOP
SWITCH CLIP
EMERGENCY STOP
SWITCH LANYARD
EMERGENCY
STOP SWITCH
INDICATORS
(Oil pressure, Overheat,
Alternator, Malfunction)
FAST IDLE
BUTTON
POWER TRIM/TILT
SWITCH (LEFT)
POWER TRIM/TILT
SWITCH (RIGHT)
GEARSHIFT/THROTTLE
CONTROL LEVERS
15
CONTROLS AND FEATURES
FUEL TANK
FUEL GAUGE
FUEL HOSE CONNECTOR
FUEL FILLER CAP
VENT KNOB
FUEL HOSE JOINT
(outboard motor side)
FUEL PRIMING BULB
FUEL TANK HOSE
ASSEMBLY
Portable Fuel Tank (optional equipment)
Fuel Tank Hose Assembly (standard equipment)
16
CONTROLS AND FEATURES
TRL (Trolling) CONTROL SWITCH
Trim Meter (optional equipment)
Tachometer
(optional equipment)
TRL (Trolling) Control Switch
Panel
(optional equipment)
17
CONTROLS AND FEATURES
IGNITION
SWITCH
ON
START
OFF
EMERGENCY STOP SWITCH
EMERGENCY STOP
SWITCH CLIP
EMERGENCY
STOP SWITCH
LANYARD
EMERGENCY STOP
SWITCH CLIP
EMERGENCY
STOP SWITCH
LANYARD
CONTROLS
Side-Mount Type
Ignition Switch
The ignition switch controls the
ignition system and the starter motor.
Turning the ignition switch key to the
START position operates the starter
motor. The key automatically returns
to the ON position when released
from the START position.
The ignition switch can be used to
start the engine only when the control
lever is in the N (neutral) position
(p.
49) and the emergency stop switch
clip is in the emergency stop switch.
Turning the ignition switch to the
OFF position stops the engine.
Emergency Stop Switch Clip and
Emergency Stop Switch
18
CONTROLS AND FEATURES
SPARE SWITCH CLIP
GEARSHIFT/THROTTLE
CONTROL LEVER
NEUTRAL RELEASE
LEVER
The emergency stop switch clip must
be inserted in the emergency stop
switch in order for the engine to start
and run. The emergency stop switch
lanyard must be attached to the
operator’s PFD (Personal Flotation
Device) or to the operator securely.
When used as described, the
emergency stop switch clip and
emergency stop switch lanyard
system stops the engine if the
operator falls away from the controls.
A spare switch clip is stored in a slot
in the control housing.
Gearshift/Throttle Control Lever
The gearshift/throttle control lever
controls engine speed and selects F
(forward), N (neutral), or R (reverse)
gears.
19
CONTROLS AND FEATURES
FAST IDLE LEVER
MINIMUM
GEARSHIFT/THROTTLE
CONTROL LEVER
MAXIMUM
MAXIMUM
SHIFT
SHIFT
30°
30°
F (FORWARD) R (REVERSE)
N (NEUTRAL)
THROTTLE OPENING
THROTTLE OPENING
MINIMUM
Moving the control lever 30° from N
(neutral) selects the gear, and further
movement increases engine speed.
The control lever automatically locks
itself in the N (neutral) position. To
move the lever out of the N (neutral)
position, you must squeeze the
neutral release lever on the underside
of the lever handle.
A friction adjuster near the base of
the control lever(s) adjusts the
operating resistance of the control
lever(s). Refer to p.
Less friction allows easier control
lever movement. More friction helps
to hold a steady throttle setting while
cruising.
64.
Fast Idle Lever
Use the fast idle lever to accelerate
engine warm-up after starting the
engine. Do not use the fast idle lever
when starting the engine.
See page 51 for engine warm-up
instructions.
20
CONTROLS AND FEATURES
N (neutral)
MAXIMUM FAST IDLE
LOWEST
POSITION
FAST IDLE LEVER
IGNITION
SWITCH
OFF
ON
START
The fast idle lever allows you to
increase the idle speed only when the
control lever is in the N (neutral)
position. Place the fast idle lever in its
lowest position to cancel the fast idle
and return the control lever to normal
operation.
Panel-Mount Type
Ignition Switch
The ignition switch controls the
ignition system and the starter motor.
Turning the ignition switch key to the
START position operates the starter
motor. The key automatically returns
to the ON position when released
from the START position.
The ignition switch can be used to
start the engine only when the control
lever is in the N (neutral) position
(p.
52) and the emergency stop switch
clip is in the emergency stop switch.
Turning the ignition switch to the
OFF position stops the engine.
21
CONTROLS AND FEATURES
EMERGENCY STOP SWITCH
EMERGENCY STOP
SWITCH CLIP
EMERGENCY
STOP SWITCH
LANYARD
EMERGENCY STOP
SWITCH CLIP
EMERGENCY
STOP SWITCH
LANYARD
Emergency Stop Switch Clip and
Emergency Stop Switch
The emergency stop switch clip must
be inserted in the emergency stop
switch in order for the engine to start
and run. The emergency stop switch
lanyard must be attached securely to
the operator or to the operator’s PFD
(Personal Flotation Device).
When used as described, the
emergency stop switch clip and
emergency stop switch lanyard
system stops the engine if the
operator falls away from the controls.
22
Gearshift/Throttle Control Lever
GEARSHIFT/THROTTLE
CONTROL LEVER
NEUTRAL
RELEASE
LEVER
GEARSHIFT/THROTTLE
CONTROL LEVER
MAXIMUM
F (FORWARD)
SHIFT
35°
N (NEUTRAL)
35°
MAXIMUM
SHIFT
R (REVERSE)
THROTTLE OPENING
MINIMUM
MINIMUM
THROTTLE OPENING
CONTROLS AND FEATURES
The gearshift/throttle control lever
controls engine speed and selects F
(forward), N (neutral), or R (reverse)
gears.
Moving the control lever 35° from N
(neutral) selects the gear, and further
movement increases engine speed.
The control lever automatically locks
itself in the N (neutral) position. To
move the lever out of the N (neutral)
position, you must squeeze the
neutral release lever on the underside
of the lever handle.
A friction adjuster near the base of
the control lever adjusts the operating
resistance of the control lever. Refer
to p.
64.
Less friction allows easier control
lever movement. More friction helps
to hold a steady throttle setting while
cruising.
23
CONTROLS AND FEATURES
FAST IDLE BUTTON
FAST IDLE BUTTON
CONTROL
LEVER
NEUTRAL
RELEASE
LEVER
Push
F (forward)
N (neutral)
R (reverse)
Pull up
Fast Idle Button
Use the fast idle button to accelerate
engine warm-up after starting the
engine. Do not use the fast idle button
when starting the engine.
See page 53 for engine warm-up
instructions.
It is necessary to position the control
lever in the N (neutral) position to
push in the fast idle button.
Return the control lever to N (neutral)
position to cancel the fast idle
operation.
The fast idle button allows you to
increase the idle speed without
engaging the drive gears. Move the
control lever toward the F (forward)
or R (reverse) position after pushing
in the fast idle button to increase the
idle speed.
24
CONTROLS AND FEATURES
IGNITION
SWITCH
OFF
ON
START
EMERGENCY STOP SWITCH
EMERGENCY STOP
SWITCH CLIP
EMERGENCY
STOP SWITCH
LANYARD
EMERGENCY STOP
SWITCH LANYARD
EMERGENCY STOP
SWITCH CLIP
Top-Mount Type
Ignition Switch
The ignition switch controls the
ignition system and the starter motor.
Turning the ignition switch key to the
START position operates the starter
motor. The key automatically returns
to the ON position when released
from the START position.
The ignition switch can be used to
start the engine only when the control
lever is in the N (neutral) position
(p.
55) and the emergency stop switch
clip is in the emergency stop switch.
Turning the ignition switch to the
OFF position stops the engine.
Emergency Stop Switch Clip and
Emergency Stop Switch
25
CONTROLS AND FEATURES
SINGLE TYPE
DUAL TYPE
GEARSHIFT/
THROTTLE
CONTROL
LEVER
GEARSHIFT/THROTTLE
CONTROL LEVERS
The emergency stop switch clip must
be inserted in the emergency stop
switch in order for the engine to start
and run. The emergency stop switch
lanyard must be attached securely to
the operator or to the operator’s PFD
(Personal Flotation Device).
When used as described, the
emergency stop switch clip and
emergency stop switch lanyard
system stops the engine if the
operator falls away from the controls.
Gearshift/Throttle Control Lever
The gearshift/throttle control lever(s)
controls engine speed and selects F
(forward), N (neutral), or R (reverse)
gears.
26
Moving the control lever 35° from N
GEARSHIFT/THROTTLE CONTROL LEVER
MAXIMUM
F (FORWARD)
N (NEUTRAL)
R (REVERSE)
MAXIMUM
SHIFT SHIFT
35°
35°
THROTTLE OPENING
MINIMUM
MINIMUM
THROTTLE OPENING
(neutral) selects the gear, and further
movement increases engine speed.
A friction adjuster inside the control
box adjusts the operating resistance
of the control lever(s). Refer to p.
64.
Less friction allows easier control
lever movement. More friction helps
to hold a steady throttle setting while
cruising.
CONTROLS AND FEATURES
27
CONTROLS AND FEATURES
FAST IDLE BUTTON
FAST IDLE BUTTON
CONTROL
LEVER
F (forward)
N (neutral)
R (reverse)
Push
Fast Idle Button
Use the fast idle button to accelerate
engine warm-up after starting the
engine. Do not use the fast idle button
when starting the engine.
See page 56 for engine warm-up
instructions.
It is necessary to position the control
lever in the N (neutral) position to
push in the fast idle button.
Return the control lever to N (neutral)
position to cancel the fast idle
operation.
The fast idle button allows you to
increase the idle speed without
engaging the drive gears. Move the
control lever toward the F (forward)
or R (reverse) position after pushing
in the fast idle button to increase the
idle speed.
28
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