TOHATSU M4C, M5B Owner's Manual
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OWNER’S
MANUAL
M 4C
M 5B
OB No.003-11068-6AF1
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 © 2016 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.
YOUR TOHATSU OUTBOARD MOTOR
ENOM00006-A
To You, Our Customer
Thank you for selecting a TOHATSU outboard motor. You are now the proud owner of an
excellent outboard motor that will service you for many years to come.
This manual should be read in its entirety and the inspection and maintenance procedures
described later in this manual should be followed carefully. Should a problem arise with the
outboard motor, please follow the troubleshooting procedures listed at the end of this
manual. If the problem persists, contact an authorized TOHATSU service shop or dealer.
Please always keep this manual together with the outboard motor as a reference to 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.
3
4
ENOF02100-0
ENOF02101-0
ENOM00005-A
Serial Number
In the space below, please record the outboard motor's serial number (indicated both on
the swivel bracket and on the cylinder block). The serial number will be needed when
ordering parts, and when making technical or warranty inquiries.
Serial Number:
Serial Number: Date of purchase:
ENOM00007-0
NOTICE: DANGER/WARNING/CAUTION/Note
Before installing, operating or otherwise handling your outboard motor, be sure to thoroughly read and understand this Owner's Manual and carefully follow all of the instructions. 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.
5
CONTENTS
1. GENERAL SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3. PARTS NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4. LABEL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
1. Mounting the outboard motor on boat . . . . . . . . . . . . . . . . . . . . . . . . . . .19
2. Remote control device installation (option) . . . . . . . . . . . . . . . . . . . . . . . . 21
6. PRE-OPERATING PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1. Fuel handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2. Engine oil recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
3. Fuel filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4. Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7. ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1. Fuel feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2. Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
3. Warming up the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
4. Forward, reverse, and acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5. Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
6. Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
7. Trim angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
8. Tilt up and down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
9. Shallow water operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
8. REMOVING AND CARRYING THE OUTBOARD MOTOR. . . . . . . . . . . . . .40
1. Removing the outboard motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
2. Carrying the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
3. Traillering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9. ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
1. Steering friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
2. Throttle grip friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10. INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1. Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2. Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
3. Off-season storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
4. Pre-season check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5. Submerged outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
6. Cold weather precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
7. Striking underwater object. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
8. Auxiliary outboard motor operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
11. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
12. TOOL KIT AND SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
13. PROPELLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
INDEX
9
1 GENERAL SAFETY INFORMATION
2. SPECIFICATIONS
3. PARTS NAME
4. LABEL LOCATIONS
5. INSTALLATION
6. PRE-OPERATING PREPARATIONS
7. ENGINE OPERATION
8. REMOVING AND CARRYING THE
OUTBOARD MOTOR
9. ADJUSTMENT
1
2
3
4
5
6
7
8
9
10.INSPECTION AND MAINTENANCE
11.TROUBLESHOOTING
12.TOOL KIT AND SPARE PARTS
13.PROPELLER TABLE
10
11
12
13
14
14
10
GENERAL SAFETY INFORMATION
ENOM00009-0
SAFE OPERATION OF BOAT
1
As the operator/driver of the boat, you are responsible for the safety of those aboard and
those in other boat around yours, and for following local boating regulations. You should
be thoroughly knowledgeable on how to correctly operate the boat, outboard motor, and
accessories. To learn about the correct operation and maintenance of the outboard motor,
please read through this manual carefully.
It is very difficult for a person standing or floating in the water to take evasive action should
he or she see a power boat heading in his/her direction, even at a slow speed. Therefore,
when your boat is in the immediate vicinity of people in the water, the outboard motor
should be shifted to neutral and shut off.
ENOW00005-0
WARNING
SERIOUS INJURY IS LIKELY IF A PERSON IN THE WATER MAKES CONTACT WITH A MOVING BOAT, GEAR HOUSING, PROPELLER, OR ANY SOLID DEVICE RIGIDLY ATTACHED TO
A BOAT OR GEAR HOUSING.
ENOM0008-A
EMERGENCY STOP SWITCH
The Emergency Stop Switch will stall the outboard motor when the stop switch lanyard is
pulled off. This stop switch lanyard has to be attached to the operator of the outboard
motor to minimize or prevent injuries from the propeller in case the operator falls overboard.
It is operator’s responsibility to use the Emergency Stop Switch Lanyard.
ENOW00004-A
WARNING
Accidental activation of the Emergency Stop Switch (such as the tether being pulled out in
heavy seas) could cause passengers to lose their balance and even fall overboard, or it
could result in loss of power in heavy seas, strong currents, or high winds. Loss of control
while mooring is another potential hazard.
To minimize accidental activation of the Emergency Stop Switch, the 500 mm (20 inch.) stop
switch lanyard is coiled and can extended to a full 1300 mm (51 inch.).
ENOM00800-A
PERSONAL FLOATATION DEVICE
As the operator/driver and passenger of the boat, you are responsible to wear a PFD (Personal Floatation Device) while on the boat.
GENERAL SAFETY INFORMATION 11
ENOM00010-0
SERVICING, REPLACEMENT PARTS & LUBRICANTS
We recommend that only an authorized service shop perform service or maintenance on
this outboard motor. Be sure to use genuine parts, genuine lubricants, or recommended
lubricants.
ENOM00011-A
MAINTENANCE
As the owner of this outboard motor, you should be acquainted with correct maintenance
procedures following maintenance section of this manual (See page 44). 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.
1
12
SPECIFICATIONS
ENOM00810-A
MODEL FEATURE
2
Ty pe MF MF
Transom heights
Tiller Handle z z
Remote Control (z)*1 (z)*1
Separate fuel tank z
Integral fuel tank z z
Manual tilt z z
*1: Option
ENOM00811-A
MODEL NAME EXAMPLE
M 5 BDL
Model M4C M5B-D
S z z
L z z
UL z
M 5 B D L
Model descrip-
tion
M (X)=Two stroke
F= Four stroke
D= Two stroke DI
Horse
power
Product
generation
- A and up
Fuel tank Shaft length
D=Integral (Dual)
fuel tank and
Separate fuel
tank
Blank=Integral
fuel tank
S= Short 15 in
L= Long 20 in
UL= Ultra long
25 in
ENOM01400-0
MF
SPECIFICATIONS 13
Item MODEL
Overall Length mm (in) 700 (27.6)
Overall Width mm (in) 310 (12.2)
S mm (in) 1,007 (39.6)
Overall Height
Transom Height
Weight
Output kW (ps) 2.9 (4) 3.68 (5)
Max. Operating Range rpm 4,500-5,500
Trolling Speed in Forward Gear
Idle Speed in Neutral Gear rpm 1,000
Engine Type 2-Stroke
Number of Cylinders 1
Bore x Stroke mm (in) 55 x 43 (2.17 x 1.69)
Piston Displacement mL (Cu in) 102 (6.22)
Exhaust System Through Hub exhaust
Cooling System Water cooling
Lubrication System Fuel Mixture
Starting System Manual starter
Ignition System Flywheel Magneto C.D. Ignition
Spark Plugs NGK BP7HS-10 or BPR7HS-10
Trim Position 6
Fuel
Fuel Tank Capacity L (US gal) 2.5 (0.66) 2.5 (0.66), 12 (3.17*)
Engine Oil Genuine motor oil or recommended one (TCW-III)
Fuel : Engine Oil Mixing Rethio 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. 195 (6.6)
Gear Shift Dog Clutch (F-N-R)
Gear Reduction Ratio 2.15 (13 : 28)
*:In case of dual fuel tank system, use it together with 12 L separate tank.
Remark: Specifications subject to change without notice.
Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
L mm (in) 1,134 (44.6)
UL mm (in) - 1,082 (22.1)
S mm (in) 435 (17.1)
L mm (in) 562 (22.1)
UL mm (in) 689 (27.1)
S kg (lb) 20.0 (44)
L kg (lb) 20.5 (45)
UL kg (lb) - 21.0 (46)
rpm 850
4C 5B-D
Unleaded regular gasoline : Pump posted 87 Octane
(research octane rating of 91)
2
3
1
20
2
3
4
5
6
10
7
8
9
11
12
13
14
15
16
18
17
19
21
23
24
25
23
24
26
27
1
5B-D Dual Fuel Tank
22
4C
ENOF02102-0
14
PARTS NAME
ENOM01401-0
4C, 5B-D
1
Air Vent Screw
2
Fuel Tank Cap
3
Tilt Handle
4
Top C owl
5
Bottom Cowl
6
Cooling Water Check Port
7
Tilt Lever
8
Anode
9
Anti-Ventilation Plate
10
Water Inlet
Propeller
11
12
Starter Handle
13
Shift Lever
14
Throttle Glip
15
Clamp Screw
16
Clamp Bracket
17
Thrust Rod
18
Oil Plug (Upper)
19
Oil Plug (Lower)
20
Steering Adjust Screw
21
Spark Plug
22
Fuel Filter
23
Choke Knob
24
Stop Switch
25
Fuel Cock Knob
26
Fuel Connector
27
Fuel Cock
ENOM00822-0
Fuel tank
PARTS NAME 15
1
1
Fuel gauge
2
Air vent screw
3
Fuel tank cap
4
Fuel connector (Engine side)
5
Primer bulb
6
Fuel connector (Fuel tank side)
2
3
3
5
6
4
ENOF02103-0
16
LABEL LOCATIONS
ENOM01402-0
Warning label locations
1
4
2
3
5
4
ENOF02104-0
1.
1
2
3
ENOF00129-A
3C8-72181-0B
Warning label regarding owner’s manual, top cowl and engine stop switch.
ENOF00005-W
2-1. Warning regarding high temperature.
2-2. Warning regarding rotating object.
2-3. Warning regarding high voltage
LABEL LOCATIONS 17
4.
Warning regarding gasoline (See
page 24).
ENOF00005-S
5.
Warning regarding gasoline (See
page 24).
ENOF00005-L
4
3.
Warning label regarding high voltage.
LABEL LOCATIONS18
ENOM01001-0
Serial number label locations
4
1. Model code(Model name)
2. Rated power
3. Dry mass weight
4. Serial No.
5. Manufacture name
6. Manufacture adress
r o t o M d r a o b t u O
1)
: r e w o P d e t a R
: s s a M
. o N l a i r e S
2)
3)
4)
5)
6)
n a p a J n i e d a M
ENOF02105-0
INSTALLATION
19
ENOM00024-B
1. Mounting the outboard 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
has been securely mounted on the boat in
accordance with the instructions below.
ENOW00009-0
WARNING
z Mounting the outboard motor without
following this manual can lead to unsafe
conditions such as poor maneuverability, lack of control or fire.
z Loose clamp screws and/or mounting
bolts can lead to the release or displacement 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 fas-
teners included in the outboard motor
package or their equivalents in terms of
size, material, quality and strength.
Tighten fasteners to the specified torque
(30 Nm (3.0 kgf) 13 ft-lb). Test cruise to
check if fasteners are tightened
securely.
z Outboard motor mounting must be per-
formed by trained service person(s)
using lift or hoist with sufficient capacity.
Keep the outboard motor in a vertical position when mounting.
5
ENOF02106-0
ENOM00025-0
Position ... Above keel line
Set engine at center of boat.
1
2
ENOF01141-0
1. Center of boat
2. Boat transom
ENOM00026-0
Transom matching
Be sure that the anti ventilation plate of the
outboard motor is 30–50 mm (1.2–21 in)
below the bottom of hull.
If the above condition cannot be met due
to the shape of the bottom of your boat,
please consult your authorized dealer.
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