TOHATSU BFT 60A, BFW 60A Owner's Manual

OWNER’S MANUAL
BFT 60A
BFW 60A
Original instructions
PGM-FI is a trademark of Honda Motor Co , Ltd registered in Japan and other countries
Thank you for purchasing a TOHATSU Outboard Motor.
This manual covers operation and maintenance of the TOHATSU BFT60A/BFW60A Outboard Motor. All information in this publication 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.
No part of this publication may be reproduced without written permission.
This manual should be considered a permanent part of the Outboard Motor and should remain with it if it is resold.
Throughout this manual, you will see safety messages proceeded by the following words and symbols. Here’s what they mean:
Indicates serious injury or death WILL result if instructions are not followed.
Indicates a strong possibility that serious personal injury or death may result if instructions are not followed.
Indicates a possibility that personal injury or equipment damage could result if instructions are not followed.
Indicates that equipment or property damage could result if instructions are not followed.
If a problem should arise, or if you have any questions about the Outboard Motor, consult an authorized TOHATSU Outboard Motor dealer.
TOHATSU Outboard Motors are designed to give safe and dependable service if operated according to instructions. Read and understand the Owner’s Manual before operating the Outboard Motor. Failure to do so could result in personal injury or equipment damage.
• Have your dealer install the tiller handle.
• The illustration may vary according to the type.
Gives helpful information.
1
This Owner’s Manual is using the
LEFT STERN BRACKET
FRAME SERIAL NUMBER
ENGINE SERIAL NUMBER
following type names when it describes the operations special to a type.
Tiller handle type: H type Remote control type: R type
The remote control type is classified into the following three categories according to the control box position.
• Side-mount type
• Panel-mount type
• To p-mount type
This Owner’s Manual describes with the side-mount type remote control box.
Check the type of your outboard motor and read this Owner’s Manual thoroughly before operation. Texts with no type indication are the information and/or procedures common to all types.
Record the frame and engine serial numbers for your reference. Refer to the serial numbers when ordering parts, and when making technical or warranty inquiries.
The frame serial number is stamped on a plate attached on the left side of the stern bracket.
Frame serial number:
The engine serial number is stamped on the upper right side of the engine.
Engine serial number:
2
Control and Feature Identification Codes
TYPE CODE Example
LRTD
Destination U: Europe, D: General Export Tilt system T: Power Trim/Tilt (with hydraulic assisted function) Control System H: Tiller Handle Control R: Remote Control Shaft Length BFT60A: L= 521 mm (20.5 in) (Long Shaft) BFW60A: L= 531 mm (20.9 in) (Long Shaft)
Model BFT60A BFW60A Type LRTD LRTU LHTD LRTU
Shaft Length Tiller Handle Remote Control Power Trim/Tilt Trim Meter Tachometer Rudder Meter Tilt Limit Mechanism Portable Fuel Tank (25 L) TRL (Trolling) Control Switch 50 Ste e ring An gle R od
Note that the types of the outboard motor differ according to the countries where they are sold.
BFT60A/BFW60A is provided with the following types according to the shaft length, control system, and tilt system.
: Optional Equipment
*

** ****
*

** **** ** ** **** ** **
– –
*
* *
* *
3
CONTENTS
1. SAFETY ........................................................................................... 7
SAFETY INFORMATION ........................................................... 7
2. SAFETY LABEL LOCATIONS.................................................... 10
CE mark location......................................................................... 12
3. COMPONENT IDENTIFICATION .............................................. 13
4. CONTROLS AND FEATURES (H type)...................................... 21
H type
Engine Switch (Ignition Switch)............................................ 21
Shift Lever.............................................................................. 22
Throttle Grip........................................................................... 23
Throttle Friction Adjuster ...................................................... 23
Emergency Stop Switch......................................................... 24
Emergency Stop Switch Lanyard/Clip................................... 24
Steering Friction Adjuster................. ..................................... 25
TRL (Trolling) Control Switch .............................................. 25
R type
SIDE-MOUNT TYPE................................................................. 26
Remote Control Lever......................................... ................... 26
Neutral Release Lever................ ............................................ 27
Engine Switch (Ignition Switch)............................................ 27
Fast Idle Lever................................................................ ........ 28
Emergency Stop Switch......................................................... 28
Emergency Stop Switch Lanyard/Clip................................... 29
Spare Emergency Stop Switch Clip (optional equipment) .... 30
TRL (Trolling) Control Switch .............................................. 30
Common
Power Trim/Tilt Switch.......................................................... 31
NMEA Interface Coupler .... ................................................... 32
Operating Hour Notification System ......... ............................ 32
Trim Meter ............................................................................. 35
Power Tilt Switch (outboard motor pan)............................... 35
Manual Relief Valve ............................................. ................. 36
Tilt Lock Lever...................................................................... 36
Oil Pressure Indicator/Buzzer................................................ 37
Overheat Indicator/Buzzer..................................................... 38
ACG Indicator/Buzzer........................................................... 39
PGM-FI Indicator/Buzzer...................................................... 40
Trim Tab................................................................................ 41
Anode..................................................................................... 42
Cooling Water Check Hole.................................................... 43
Cooling Water Intake Port..................................................... 43
Engine Cover Fixing Lever ................................................... 44
Fuel Filler Cap (equipped type)................................ ............. 44
Fuel Gauge.. ........................................................................... 45
Fuel Line Connector And Joint ............................................. 45
Tachometer ............................................................................ 45
Rudder Meter......................................................................... 46
5. INSTALLATION........................................................................... 47
Transom Height .......................................................................... 47
Location...................................................................................... 48
Installation Height ............. .. ....................................................... 48
Outboard Motor Installation ....................................................... 49
Outboard Motor Angle Inspection (Cruising) ............................ 50
Battery Connections.................................................................... 51
Remote Control Installation. ............................................... ........ 53
<Remote Control Box Location> .......................................... 53
<Remote Control Cable Length> .......................................... 54
Propeller Selection...................................................................... 54
4
CONTENTS
6. PRE-OPERATION CHECKS ........................................................ 55
Engine Cover Removal/Installation ............................................ 55
Engine Oil ................................................................................... 56
Fuel........ ............................................... ....................................... 58
GASOLINE CONTAINING ALCOHOL.............................. 59
Propeller and Cotter Pin Inspection .................. .. ........................ 60
Tiller Handle Height/Angle Adjustment (H type) ...................... 61
Steering Handle Friction (H type)................................ ............... 62
Remote Control Lever Friction (Side-mount type) ..................... 62
Fuel Filter/Water Separator......................................................... 62
Battery......................................................................................... 63
Other Checks............................ ............................................... .... 64
7. STARTING THE ENGINE............................................................ 65
Fuel Line Connection.................................................................. 65
Fuel Priming................................................................................ 66
Starting the Engine (H type) ........... ............................................ 67
Starting the Engine (R type)... ............................................... ...... 71
Emergency Starting..................................................................... 74
8. OPERATION.................................................................................. 80
Break-in Procedure................. ............................................... ...... 80
H type
Gear Shifting............ .............................................................. 81
Steering .................. ................................................................ 82
Cruising.................................................................................. 83
R type
Gear Shifting............ .............................................................. 85
Cruising.................................................................................. 86
Common
TRL (Trolling Control) Switch.............................................. 88
Trimming the Outboard Motor.............................................. 89
Trim Meter............................................................................. 91
Tilting the Outboard Motor ................................................... 92
Moorage........................................ ......................................... 93
Manual Relief Valve ............................................. ................. 94
Power Tilt Switch (outboard motor pan)............................... 94
Trim Tab Adjustment ................... ......................................... 95
Engine Protection System...................................................... 97
<Engine Oil Pressure, Overheat, PGM-FI and
ACG Warning Systems> ................................................97
<Over-rev Limiter> .......................................................... 101
<Anode> .......................................................................... 101
Shallow Water Operation ............. .. ..................................... 102
Multiple Outboard Motors................................................... 102
9. STOPPING THE ENGINE.......................................................... 103
Emergency Engine Stop ......................................................... .. 103
Normal Engine Stop ................................................................. 104
(H type)........................................... ..................................... 104
(R type)................................................................................ 105
10. TRANSPORTING ..................................................................... 106
Fuel Line Disconnection........................................................... 106
Transporting.......... .................................................................... 107
Trailering ....................... .. ......................................................... 109
11. CLEANING AND FLUSHING................................................. 110
5
CONTENTS
12. MAINTENANCE....................................................................... 111
Tool Kit, Spare and Emergency Parts............. .......................... 112
MAINTENANCE SCHEDULE................... ............................. 113
Engine Oil ................................................................................. 115
Spark Plugs................................................................................ 116
Battery....................................................................................... 118
Lubrication ................................................................................ 121
Fuel Filter/Water Separator....................................................... 123
Fuel Tank and Tank Filter......................................................... 126
EMISSION CONTROL SYSTEM ........................................... 127
Fuse ............................................... ............................................ 128
Propeller......... ........................................................................... 130
Submerged Outboard Motor ..................................................... 132
13. STORAGE.................................................................................. 134
Fuel........ ............................................... ..................................... 134
Vapor Separator Draining ......................................................... 135
Engine Oil ................................................................................. 136
Battery Storage.......................................................................... 137
Outboard Motor Position........................................................... 138
14. DISPOSAL ................................................................................. 139
15. TROUBLESHOOTING ............................................................. 140
16. SPECIFICATIONS..................................................................... 141
17. ‘‘EC DECLARATION OF CONFORMITY’’
CONTENT OUTLINE............................................................... 144
18. INDEX........................................................................................ 149
6

SAFETY INFORMATION

• TOHATSU outboard motor is designed to give safe and dependable service if operated according to instructions. Read and understand the Owner’s Manual before operating the outboard motor. Failure to do so could result in personal injury or equipment damage.
• Gasoline is harmful or fatal if swallowed. Keep the fuel tank out of reach of children.
• Gasoline is extremely flammable and is explosive under certain conditions. Refuel in a well-ventilated area with the engine stopped.
• Do not smoke or allow flames or sparks where the engine is refueled or where gasoline is stored.
• Do not overfill the fuel tank. After refueling make sure that the fuel filler cap is closed properly and securely.
• Be careful not to spill any fuel while refueling. Spilled fuel or fuel vapor may ignite. If any fuel is spilled make sure that the area is dry before starting the engine.
For your safety and the safety of others, pay special attention to these precautions.
Operator Responsibility

1. SAFETY

7
SAFETY
Shift to the neutral position and then shift to the reverse position at low engine speed. Do not shift to the reverse position suddenly at high engine speed.
Moving parts can injure you. Install the engine cover after emergency starting the engine. Do not operate the outboard motor without the engine cover.
• Know how to stop the engine quickly in case of emergency. Understand the use of all controls.
• Do not exceed the boat manufacturer’s power recommendation, and be sure that the outboard motor is properly mounted.
• Never permit anyone to operate the outboard motor without proper instruction.
• Stop the engine immediately if anyone falls overboard.
• Do not run the engine while the boat is near anyone in the water.
• Attach the emergency stop switch lanyard securely to the operator.
• Before operating the outboard motor, familiarize yourself with all laws and regulations relating to boating and the use of outboard motors.
• Do not attempt to modify the outboard motor.
• Always wear a life-jacket when on board.
• Do not operate the outboard motor without the engine cover. Exposed moving parts can cause injury.
• Do not remove any guards, labels, shields, covers or safety devices; they are installed for your safety.
8
SAFETY
Fire and Burn Hazards
Gasoline is extremely flammable, and gasoline vapor can explode. Use extreme care when handling gasoline. KEEP OUT OF REACH OF CHILDREN.
• Remove the fuel tank from the boat for refueling.
• Refuel in a well-ventilated area with the engine stopped. Keep flames and sparks away, and do not smoke in the area.
• Refuel carefully to avoid spilling fuel. A void overfilling the fuel tank (there should be no fuel in the filler neck). After refueling, tighten the fuel filler cap securely. If any fuel is spilled, make sure the area is dry before starting the engine.
The engine and exhaust system become very hot during operation and remain hot for a while after stopping. Contact with hot engine components can cause burns and may ignite some materials.
• Avo id touching a hot engine or exhaust system.
• Allow the engine to cool before performing maintenance or transporting.
Carbon Monoxide Poisoning Hazard
Exhaust contains poisonous carbon monoxide, a colorless and odorless gas. Breathing exhaust can cause loss of consciousness and may lead to death.
• If you run the engine in an area that is confined, or even partially enclosed, the air can become contaminated with a dangerous amount of exhaust gas. To keep exhaust gas from building up, provide adequate ventilation.
9

2. SAFETY LABEL LOCATIONS

READ OWNER’S MANUAL
READ OWNER’S MANUAL GEAR SHIFTING
READ OWNER’S MANUAL
EMERGENCY ENGINE STARTING
[Equipped type]
These labels are in the locations shown. They warn you of potential hazards that can cause serious injury. Read the labels and safety notes and precautions described in this manual carefully. If a label comes off or becomes hard to read, contact your TOHATSU outboard motor dealer for a replacement.
10
PORTABLE FUEL TANK
FUEL CAUTION
FUEL CAUTION
SAFETY LABEL LOCATIONS
11
CE MARK
Name and address of manufacturer and authorized representative are written in the “EC Declaration of Conformity” CONTENT OUTLINE in this Owner’s Manual.
Year code D E F G H J Year of manufacture 2013 2014 2015 2016 2017 2018
(1) Model name (2) Engine family name (3) Year code (4) Rated power (5) Dry mass (weight) (with propeller,
without battery cable) (6) Country of manufacture (7) Frame number (8) Manufacturer and address (9) Name and address of authorized
representative (10)The identification number of the
notified body
(1) (2)
(3)
(4) (5)
(6)
(7) (8)
(9)
(10)
SAFETY LABEL LOCATIONS
CE mark location [U type only]
12
[H (Tiller Handle) type]
ENGINE COVER FIXING LEVER (front)
TILLER HANDLE
FRAME SERIAL NUMBER
ANODE
PROPELLER (equipped type or optional equipment)
EXHAUST PORT/WATER OUTLET PORT
TRIM TAB
ANODE (each side)
COOLING WATER CHECK HOLE
IDLE PORT
ENGINE COVER FIXING LEVER (rear)
ENGINE COVER
POWER TILT SWITCH
FLUSH PORT CONNECTOR
ENGINE OIL DRAIN BOLT
ANTICAVITATION PLATE
GEAR OIL DRAIN PLUG SCREW
COOLING W ATER INTAKE PORT (each side)
GEAR OIL LEVEL PLUG SCREW
MANUAL RELIEF VALVE
STERN BRACKET
TILT LOCK LEVER
FUEL HOSE

3. COMPONENT IDENTIFICATION

13
COMPONENT IDENTIFICATION
ENGINE SERIAL NUMBER
FUEL FILTER/WATER SEPARATOR (inside strainer cup)
INTERFACE
COUPLER
MAIN FUSE BOX
ACG FUSE
OIL LEVEL DIPSTICK
SPARK PLUG CAPS
ENGINE OIL FILLER CAP
14
TILLER HANDLE
INDICATORS (Oil pressure, Overheat, ACG, PGM-FI)
ENGINE SWITCH
ENGINE SWITCH KEY
STEERING FRICTION ADJUSTER
FUEL HOSE
EMERGENCY STOP SWITCH CLIP
EMERGENCY STOP SWITCH LANYARD
EMERGENCY STOP SWITCH
POWER TRIM/TILT SWITCH
SPARE EMERGENCY STOP SWITCH CLIP
Store the spare emergency stop switch clip in the tool bag.
TRL (Trolling Control) SWITCH
SHIFT LEVER
THROTTLE FRICTION ADJUSTER
THROTTLE GRIP
COMPONENT IDENTIFICATION
15
COMPONENT IDENTIFICATION
ENGINE COVER FIXING LEVER (front)
FRAME SERIAL NUMBER
ANODE
PROPELLER (equipped type or optional equipment)
EXHAUST PORT/WATER OUTLET PORT
TRIM TAB
ANODE (each side)
COOLING WATER CHECK HOLE
IDLE PORT
ENGINE COVER FIXING LEVER (rear)
ENGINE COVER
POWER TILT SWITCH
FLUSH PORT CONNECTOR
ENGINE OIL DRAIN BOLT
ANTICAVITATION PLATE
GEAR OIL DRAIN PLUG SCREW
COOLING W A TER INTAKE PORT (each side)
GEAR OIL LEVEL PLUG SCREW
MANUAL RELIEF VALVE
STERN BRACKET
TIL T LOCK LEVER
FUEL HOSE
[R (Remote Control) type]
16
ENGINE SERIAL NUMBER
FUEL FILTER/WATER SEPARATOR (inside strainer cup)
INTERFACE COUPLER
ACG FUSE
MAIN FUSE BOX
OIL LEVEL DIPSTICK
SPARK PLUG CAPS
ENGINE OIL FILLER CAP
COMPONENT IDENTIFICATION
17
COMPONENT IDENTIFICATION
REMOTE CONTROL LEVER
POWER TRIM/TILT SWITCH
CONTROL LEVER FRICTION ADJUSTER
EMERGENCY STOP SWITCH LANYARD
EMERGENCY STOP SWITCH CLIP
EMERGENCY STOP SWITCH
ENGINE SWITCH KEY
ENGINE SWITCH
BUZZER (inside)
F A ST IDLE LEVER
INDICATORS (Oil pressure, Overheat, ACG, PGM-FI)
NEUTRAL RELEASE LEVER
TRL (Trolling) CONTROL SWITCH
SPARE EMERGENCY ST OP SWITCH CLIP
Store the spare emergency stop switch clip in the tool bag.
REMOTE CONTROL BOX (R type) (equipped type or optional equipment)
SIDE-MOUNT TYPE
18
[Common]
FUEL GAUGE
FUEL FILLER CAP
FUEL FILLER CAP VENT KNOB
FUEL LINE JOINT (outboard motor side)
PRIMING BULB
FUEL TANK TUBE ASSEMBLY
PORTABLE FUEL TANK (equipped type or optional equipment)
COMPONENT IDENTIFICATION
19
COMPONENT IDENTIFICATION
TRL (Trolling Control) SWITCH
TACHOMETER
(equipped type or optional equipment)
TRIM METER
(equipped type or optional equipment)
RUDDER METER
(optional equipment: R type)
TRL (Trolling Control) SWITCH PANEL
(optional equipment: R type)
20
ON
START
OFF

ENGINE SWITCH (IGNITION SWITCH)

OFF ON START
SHIFT LEVER
NEUTRAL
NEUTRAL
Engine Switch (Ignition Switch)
This tiller handle is equipped with an automotive type engine switch.
Key positions: START: to start the engine. ON: to run the engine after
starting.
OFF: to stop the engine
(IGNITION OFF).
Do not leave the engine switch (ignition switch) ON (key in ON position) when the engine is not running as the battery will discharge.
The starter motor will not work unless the shift lever is in the NEUTRAL position.

4. CONTROLS AND FEATURES (H type)

21
CONTROLS AND FEATURES (H type)

Shift Lever

NEUTRAL
REVERSE
FORWARD
SHIFT LEVER
FORWARDREVERSE
NEUTRAL
SLOW
THROTTLE GRIP
SLOW
SHIFT LEVER
Use the shift lever to run the boat in forward or reverse gear, or to cut off the engine power from the propeller. There are three positions for the shift lever.
FORWARD: NEUTRAL:
REVERSE:
22
The boat moves ahead. The engine power is cut off from the propeller. The boat does not move. The boat reverses.
The shift lever will not move unless the throttle grip is in the fully closed position.
You can chose which side to have the shift lever installed. Consult your authorized TOHATSU outboard motor dealer.
CONTROLS AND FEATURES (H type)

THROTTLE GRIP

THROTTLE INDICATOR
FAST START
SLOW

THROTTLE FRICTION ADJUSTER

RELEASE
THROTTLE GRIP
FIX
Throttle Grip
Turn the grip clockwise or counterclockwise to adjust the engine speed. Turning the grip in the direction shown by arrow increases the engine speed.
The curve on the grip indicates the engine speed.
Throttle Friction Adjuster
The throttle friction adjuster adjusts resistance to throttle grip rotation.
Turn the adjuster clockwise to increase friction for holding a throttle setting while cruising.
Turn the adjuster counterclockwise to decrease friction for easy throttle grip rotation.
23
CONTROLS AND FEATURES (H type)

EMERGENCY STOP SWITCH

STOP

Emergency Stop Switch Lanyard/Clip

EMERGENCY STOP SWITCH CLIP
EMERGENCY STOP SWITCH LANYARD
STOP
EMERGENCY STOP SWITCH CLIP
EMERGENCY STOP SWITCH LANYARD
EMERGENCY STOP SWITCH
Emergency Stop Switch
Press the emergency stop switch to stop the engine.
24
The emergency stop switch lanyard is provided to stop the engine immediately when the operator falls overboard or away from the outboard motor.
The engine stops when the clip at the end of the emergency stop switch lanyard is pulled out of the emergency stop switch.
When operating the outboard motor, be sure to attach one end of the emergency stop switch lanyard securely to the operator.
If the emergency stop switch lanyard is not set, the boat might run out of control when the operator, for example, falls overboard and is not able to operate the outboard motor.
For the sake of the operator’s and the passengers’ safety, be sure to set the emergency stop switch clip located at one end of the emergency stop switch lanyard with the emergency stop switch. Attach the other end of the emergency stop switch lanyard securely to the operator.
CONTROLS AND FEATURES (H type)
SPARE EMERGENCY STOP SWITCH CLIP

STEERING FRICTION ADJUSTER

To increase friction (LOCK)
To decrease friction (FREE)
TROLLING CONTROL SWITCH
DOWN UP
The engine does not start unless the emergency stop switch clip is set on the emergency stop switch.
Store the spare emergency stop switch clip in the tool bag. Use the spare emergency stop switch clip to make the disabled engine start when the emergency stop switch lanyard is not available as, for example, when the operator falls overboard.
Steering Friction Adjuster
The steering friction adjuster adjusts steering resistance.
Less friction allows the outboard motor to turn more easily. More friction helps to hold a steady course while cruising or to prevent the outboard motor from swinging while trailering the boat.

TRL (Trolling) Control Switch

The engine speed can be adjusted with the trolling control switch when in trolling mode.
If you press and hold the TRL control switch while cruising with the throttle closed, the mode changes to trolling mode.
25
CONTROLS AND FEATURES (R type)
SIDE-MOUNT TYPE Remote Control Lever

REMOTE CONTROL LEVER

NEUTRAL RELEASE LEVER
FORWARD NEUTRAL REVERSE
REMOTE CONTROL LEVER
MAXIMUM
THROTTLE OPENING
MINIMUM
FORWARD
SHIFT
32° 32°
SHIFT
NEUTRAL
MINIMUM
REVERSE
THROTTLE OPENING
MAXIMUM
Shifting gear into forward, reverse, or neutral and the engine speed adjustment can be performed with the remote control lever. It is necessary to pull up the neutral release lever to operate the remote control lever.
26
FORWARD: Moving the lever to the FORWARD position (i.e. approximately 32° from the NEUTRAL position) engages the gear into forward. Moving the lever further from the FORWARD position will increase the throttle opening and the boat forward speed.
NEUTRAL: Engine power is cut off from the propeller.
REVERSE: Moving the lever to the REVERSE position (i.e. approximately 32° from the NEUTRAL position) engages the gear into reverse. Moving the lever further from the REVERSE position will increase the throttle opening and the boat reverse speed.
CONTROLS AND FEATURES (R type)
REMOTE CONTROL LEVER

NEUTRAL RELEASE LEVER

ENGINE SWITCH
START
ON
OFF
Neutral Release Lever
The neutral release lever is set on the remote control lever to prevent an accidental operation of the remote control lever. The remote control lever does not operate unless it is moved while pulling the neutral release lever up.

Engine Switch (Ignition Switch)

Do not leave the engine switch (ignition switch) ON (key in ON position) when the engine is not running as the battery will discharge.
The starter motor will not work unless the remote control lever is in the NEUTRAL position, and the clip is in the emergency stop switch.
This remote control is equipped with an automotive type engine switch. On the side-mount type, the engine switch locates on your side near the remote control box.
Key positions: START: to start the engine. ON: to run the engine after
starting.
OFF: to stop the engine
(IGNITION OFF).
27
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