TOHATSU MD 50B2, MD 40B2, MD 115B2, MD 75C2, MD90C2 Owner's Manual

MANUAL

30B2 40B2

50B2

115A2

MD

OWNER’S

OB No.003-11075-9

Copyright © 2009 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.

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.

!

YOUR TOHATSU OUTBOARD MOTOR

OWNER REGISTRATION AND IDENTIFICATION

Upon purchasing this product, be sure that the WARRANTY CARD is correctly and completely ﬁlled out and mailed to the addressee noted there on. This WARRANTY CARD identiﬁes you as the legal owner of the product and serves as your warranty registration.

IF THIS PROCEDURE IS NOT FOLLOWED, YOUR OUTBOARD MOTOR WILL NOT BE COVERED BY THE APPLICABLE LIMITED WARRANTY.

PRE-DELIVERY CHECK

Be sure that the product has been checked by an authorized TOHATSU dealer before you take delivery.

Limited Warranty

Please refer to the TOHATSU outboard motor Limited warranty provided to you with this product, the terms and conditions of which, as amended from time to time, are incorporated by reference into the manual.

Serial Number

In the space below, please record the outboard motor's serial number (indicated both on the lower motor cover and on the cylinder block). The serial number will be needed in the event of theft or to quickly identifying the outboard motor type.

Serial Number :

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.

We hope you will enjoy your outboard motor and wish you good luck in your boating adventures.

TOHATSU CORPORATION

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・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

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5

6

7

8

9

10

11

12

13

GENERAL SAFETY INFORMATION SPECIFICATIONS NAMES OF PARTS INSTALLATION

1. Mounting the outboard motor on boat

2. Propeller Selection

3. Installing the remote control devices

4. Installing the meters

5. Installing the drag link assembly

6. Installing the battery

PRE-OPERATING PREPARATIONS

1.Gasoline and engine oil

2.Break-in

3.Warning system

ENGINE OPERATION

1.Starting

2.Warming up the engine

3.Forward and reverse

4.Shallow water running

5.Stopping the engine

6.Trim angle

7.Mooring with the engine tilted up

REMOVING AND CARRYING THE OUTBOARD MOTOR

1.Removing the outboard motor

2.Carrying the outboard motor

3.Storing the outboard motor

TRAILERING ADJUSTMENT

1.Remoto control lever load

2.Trim tab adjustment

3.Steering load adjustment

4.Throttle grip turning load adjustment

INSPECTION AND MAINTENANCE

1.Daily inspection

2.Periodic inspection

3.Off-season storage

4.Pre-season check

5.Checking after striking underwater object

6.If the engine becomes submerged in water

7.Precautions in cold weather

TROUBLESHOOTING TOOL KIT AND SPARE PARTS OPTIONAL ACCESSORIES PROPELLER TABLE

8 10 14 18 18 21 22 27 29 30 32 32 35 36 39 39 45 46 48 50 52 55 58 58 58 59 60 61 61 61 62 62 63 64 68 74 76 77 77 77 78 80 82 84

CONTENTS

7

1. SPECIFICATIONS

2. NAMES OF PARTS

3. INSTALLATION

4.PRE-OPERATING PREPARATIONS

5.ENGINE OPERATION

6.REMOVING AND CARRYING THE MOTOR

7.TRAILERING

8.ADJUSTMENT

9.INSPECTION AND MAINTENANCE

10.TROUBLESHOOTING

11.TOOL KIT AND SPARE PARTS

12.OPTIONAL ACCESSORIES

13.PROPELLER TABLE

1

2

3

4

5

6

7

8

9

10

11

12

13

GENERAL SAFETY INFORMATION

INDEX

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.

EMERGENCY STOP SWITCH

The Emergency Stop Switch will stall the outboard motor when the stop switch tether is pulled off. This stop switch tether can be attached to the operator of the outboard motor to minimize or prevent injuries from the propeller in case the operator falls overboard. We highly recommend use of the Emergency Stop Switch tether.

Failure to observe will result in severe personal injury or death, and possibly property damage.

!



Note

This instruction provides special information to facilitate the use or maintenance of the outboard motor or to clarify important points.

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

!



!



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

GENERAL SAFETY INFORMATION

!



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 tether is coiled and can extended to a full 1,300 mm (51 inch.).

SAFE OPERATION OF BOAT

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.

SERVICING, REPLACEMENT PARTS & LUBRICANTS

We recommend that only an authorized service shop perfor m service or maintenance on this outboard motor. Be sure to use genuine parts, genuine lubricants, or recommended lubricants.

MAINTENANCE

As the owner of this outboard motor, you should be acquainted with correct maintenance procedures. 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.

MOUNTING

Outboard motor mounting must be performed by trained service person(s) using lift or hoist with sufﬁcient capacity.

!



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.

10

14

13

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11

10

9

8

7

6

5

4

3

2

1

MODEL 30B2 40B2

Item EPTO EFTO EFO

Overall Length mm (in)

630 (24.8) 1,120 (44.1)

Overall Width mm (in)

345 (13.6) 384 (15.1)

Overall Height S·L·UL mm (in)

1,227 (48.3) · 1,354 (53.3) · 1,481 (58.3)

Transom Height S·L·UL

mm (in)

403 (15.9) · 530 (20.9) · 657 (25.9)

Weight

S kg (lb)

- - -

L kg (lb)

94.5 (208) 97.5 (215) 89.5 (197)

UL kg (lb)

- - -

Output kW (Hp)

22.1 (30) 29.4 (40)

Max. Operating Range rpm

4,750 - 5,750

Engine Type

Direct fuel injection

Number of Cylinder

3

Bore ×Stroke mm (in)

68 × 64 (2.68 × 2.52)

Piston Displacement mL (Cu in)

697 (42.5)

Exhaust System

Through hub exhaust

Cooling System

Water cooling

Engine Lubrication

Oil injection

Starting System

Electric starter motor

Ignition System

Inductive Ignition

Spark Plug

NGK IZFR6J

Alternator

12V,280W (Max.)

Trim Position

4 6

Engine Oil

Genuine Motor Oil or recommended one

Gear Oil

Genuine Gear Oil or API GL5,

SAE #80 to #90, approx. 500mL

Fuel Tank Capacity L (US gal)

25 (6.6)

Engine Oil Capacity L (US gal)

Approx. 2.0 (0.53)

Gear Reduction Ratio

1.85 (13 : 24)

Fuel

Unleaded regular gasoline : Pump posted 87 Octane

(research octane rating of 91)

30B2 , 40B2

SPECIFICATIONS

※

This speciﬁcations might change without a previous notice.

11

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2

3

4

5

6

7

8

9

10

11

12

13

SPECIFICATIONS

MODEL 50B2

Item EPTO EFTO EFO

Overall Length mm (in)

630 (24.8) 1,120 (44.1)

Overall Width mm (in)

345 (13.6) 384 (15.1)

Overall Height S·L·UL mm (in)

1,227 (48.3) · 1,354 (53.3) · 1,481 (58.3)

Transom Height S·L·UL

mm (in)

403 (15.9) · 530 (20.9) · 657 (25.9)

Weight

S kg (lb)

93.5 (206) 96.5 (213) 88.5 (195)

L kg (lb)

94.5 (208) 97.5 (215) 89.5 (197)

UL kg (lb)

97 (214) 100 (220) 92 (203)

Output kW (Hp)

29.4 (40) 36.8 (50)

Max. Operating Range rpm

5,150 - 5,850

Engine Type

Direct fuel injection

Number of Cylinder

3

Bore ×Stroke mm (in)

68 × 64 (2.68 × 2.52)

Piston Displacement mL (Cu in)

697 (42.5)

Exhaust System

Through hub exhaust

Cooling System

Water cooling

Engine Lubrication

Oil injection

Starting System

Electric starter motor

Ignition System

Inductive Ignition

Spark Plug

NGK IZFR6J

Alternator

12V,280W (Max.)

Trim Position

4 6

Engine Oil

Genuine Motor Oil or recommended one

Gear Oil

Genuine Gear Oil or API GL5,

SAE #80 to #90, approx. 500mL

Fuel Tank Capacity L (US gal)

25 (6.6)

Engine Oil Capacity L (US gal)

Approx. 2.0 (0.53)

Gear Reduction Ratio

1.85 (13 : 24)

Fuel

Unleaded regular gasoline : Pump posted 87 Octane

(research octane rating of 91)

50B2

※

This speciﬁcations might change without a previous notice.

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14

13

12

11

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9

8

7

6

5

4

3

2

1

SPECIFICATIONS

MODEL W50B2

Item EPTO EFTO

Overall Length mm (in)

630 (24.8) 1,120 (44.1)

Overall Width mm (in)

345 (13.6) 384 (15.1)

Overall Height L·UL mm (in)

1,415 (55.7) · 1,542 (60.7)

Transom Height L·UL

mm (in)

550 (21.7) · 677 (26.7)

Weight

L kg (lb)

100.5 (222) 103.5 (228)

UL kg (lb)

101.5 (224) 104.5 (230)

Output kW (Hp)

36.8 (50)

Max. Operating Range rpm

5,150 - 5,850

Engine Type

Direct fuel injection

Number of Cylinder

3

Bore ×Stroke mm (in)

68 × 64 (2.68 × 2.52)

Piston Displacement mL (Cu in)

697 (42.5)

Exhaust System

Through hub exhaust

Cooling System

Water cooling

Engine Lubrication

Oil injection

Starting System

Electric starter motor

Ignition System

Inductive Ignition

Spark Plug

NGK IZFR6J

Alternator

12V,280W (Max)

Trim Position

4

Engine Oil

Genuine Motor Oil or recommendedone

Gear Oil

Genuine Gear Oil or API GL5,

SAE #80 to #90, approx. 700mL

Fuel Tank Capacity L (US gal)

25 (6.6)

Engine Oil Capacity L (US gal)

Approx. 2.0 (0.53)

Gear Reduction Ratio

1.92 (12 : 23)

Fuel

Unleaded regular gasoline : Pump posted 87 Octane

(research octane rating of 91)

W50B2

※

This speciﬁcations might change without a previous notice.

13

1

2

3

4

5

6

7

8

9

10

11

12

13

SPECIFICATIONS

115A2

※

This speciﬁcations might change without a previous notice.

MODEL 115A2

Item EPTO

Overall Length mm (in)

800 (31.5)

Overall Width mm (in)

495 (19.5)

Overall Height L·UL mm (in)

1,640 (64.6) · 1,767 (69.6)

Transom Height L·UL

mm (in)

517 (20.4) · 644 (25.4)

Weight

L·UL kg (lb)

178 (392) · 181 (399)

Output kW (Hp)

84.6 (115)

Max. Operating Range rpm

5,150 - 5,850

Engine Type

Direct fuel injection

Number of Cylinder

4

Bore

×

Stroke mm (in)

88 × 72.7 (3.46 × 2.86)

Piston Displacement mL (Cu in)

1,768 (107.9)

Exhaust System

Through hub exhaust

Cooling System

Water cooling

Engine Lubrication

Oil injection

Starting System

Electric starter motor

Ignition System

Inductive ignition

Spark Plug

NGK IZFR5J

Alternator

12V,490W (Max.)

Trim Position

2

Engine Oil

Genuine Motor Oil or recommended one

Gear Oil

Genuine Gear Oil or API GL5,

SAE #80 to #90, approx. 900mL

Fuel Tank Capacity L (US gal)

-

Engine Oil Capacity L (US gal)

Approx. 6.7 (1.77)

Gear Reduction Ratio

2.0 (13:26)

Fuel

Unleaded regular gasoline : Pump posted 87 Octane

(research octane rating of 91)

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12

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8

7

6

5

4

3

2

1

EFO / 40B2 , 50B2

NAMES OF PARTS

①

②

③

④

⑤

⑥

⑦

⑧

Tilt Handle Top Cowl Hook Lever Water Check Port Reverse Lock Lever Water Plug Anti-ventilation Plate Trim Tab

⑨

⑩

○

11

○

12

○

13

○

14

○

15

○

16

Propeller Oil Plug (lower) Water Inlet Oil Plug(upper) Clamp Bracket Thrust Rod Clamp Screw Throttle Grip

○

17

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18

○

19

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20

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21

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22

Stop Switch Shift Lever Anode Pilot Lamp Main Switch Battery Cords

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1

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2

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3

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8

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9

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10

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11

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13

○

14

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15

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16

○

17

○

18

○

19

○

20

○

21

○

22

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12

○

4

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5

○

6

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7

15

1

2

3

4

5

6

7

8

9

10

11

12

13

EFTO / 30B2 , 40B2 , 50B2 , W50B2

NAMES OF PARTS

○

1

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2

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3

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8

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9

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10

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10

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11

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13

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14

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15

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16

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17

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18

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24

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22

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19

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20

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23

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21

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12

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4

○

5

○

6

○6○

12

○

7

[W50]

①

②

③

④

⑤

⑥

⑦

⑧

Tilt Handle Top Cowl Hook Lever Water Check Port Tilt Stopper Water Plug Anti-ventilation Plate Trim Tab

⑨

⑩

○

11

○

12

○

13

○

14

○

15

○

16

Propeller Oil Plug (lower) Water Inlet Oil Plug(upper) Clamp Bracket Thrust Rod Clamp Screw Throttle Grip

○

17

○

18

○

19

○

20

○

21

○

22

○

23

○

24

Shift Lever Stop Switch Pilot Lamp Main Switch Battery Cords Power Trim & Tilt Anode Power Trim & Tilt Switch

16

14

13

12

11

10

9

8

7

6

5

4

3

2

1

NAMES OF PARTS

EFTO / 30B2 , 40B2 , 50B2 , W50B2

①

②

③

④

⑤

⑥

⑦

⑧

Tilt Handle Top Cowl Hook Lever Water Check Port Tilt Stopper Water Plug Anti-ventilation Plate Trim Tab

⑨

⑩

○

11

○

12

○

13

○

14

○

15

○

16

Propeller Oil Plug (lower) Water Inlet Oil Plug(upper) Clamp Bracket Thrust Rod Clamp Screw Filler Lid

○

17

○

18

○

19

○

20

○

21

Fuel Connector Power Trim & Tilt Switch Battery Cords Power Trim & Tilt Anode

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1

○

2

○

3

○

8

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9

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10

○

11

○

13

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14

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15

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16

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17

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18

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19

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○6○

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[W50]

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EPTO / 115A2

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Remote Control Box Remote Control Lever Power Trim & Tilt Switch Free Accel Lever Main Switch Harness B Stop Switch

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27

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28

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29

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30

Fuel Tank Air Vent Screw Fuel Connector Primer Bulb

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31

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Tachometer

Trim Meter

Note

These parts for model 115A2 are not enclosed in the engine package.

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30

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28

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NAMES OF PARTS

Installation

■

Single-engine Installation

Position the outboard engine at the exact center of the stern, and mount it using a cushioning pad or plate.

■

Twin-engine Installation

W h e n i n s t a l l i n g tw o o u t b o a r d engines, be sure to keep an interval of 470~660mm (for 40,50,70 and 90 models) or 700~890mm (for 115 model) between the two.

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

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.

1. Mounting the outboard motor on boat

INSTALLATION

●

Before beginning the running test,

check that the boat with maximum capacity loading ﬂoats on the water in a proper attitude. Check the position of water surface on the driveshaft housing. If the water surface is near the bottom cowling, in high waves, water may enter the engine cylinders.

●

Incorrect outboard motor mounting

height or existence of underwater object(s), such as hull bottom design, bottom surface conditions or underwater accessories, can cause water spray possibly reaching the engine through an opening of the bottom cowling during cruising. Exposing engine to such conditions for extended periods can lead to severe engine damage.

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

A A

Note

Consult your authorized dealer to receive the proper instructions or ask your dealer to mount the motor as necessary.

40 - 90 : 470 - 660mm

(18.5 - 26.0 in)

115 : 700 - 890mm

(27.6 - 35.0 in)

■

Transom Height

Install the engine with the Anti-ventilation Plate at a level 10~30mm(0.4~1.2in.) below the bottom of the boat.

■

Transom Matching

Be sure that anti ventilation 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 the shape of your boat, please consult your authorized dealer.

If the hei ght di ffe ren ce exc eeds 10~30mm (0.4~1.2 in) engine power performance is likely to be reduced as a result of increased water resistance to the gear case assembly.

■

Attaching the Clamp Bracket

After positioning the Clamp Bracket, ﬁx it with clamp screw then drill four holes in the transom board, matching the holes in the Clamp Bracket. Secure the engine with the supplied bolts (M12×105mm) and nuts, Be sure to use the washers. Use the larger diameter washers inside of the transom board and use the small diameter washers outside of the clamp bracket. The mounting holes may be drilled be fo r e h a n d by refer r i n g to th e dimensional drawing.

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INSTALLATION

Anti-ventilation Plate

10~30mm (0.4~1.2 in.)

Overheating may occur if the Antiventilation Plate is at a level higher than the bottom of the boat, as a result of a lack of cooling water.

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●

Mounting the outboard motor without

following this manual can lead to unsafe conditions such as poor maneuverability, going out of control or ﬁre disaster.

●

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 (3.0kgf)13ft·lb). Check the fasteners for tightness from time to time.

●

Be sure to use outboard mounting

fasteners 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 (3.0kgf)13ft·lb). Test cruise to check if fasteners are tightened securely.

●

Outboard motor mounting must

be performed by trained service person(s) using lift or hoist with sufﬁcient capacity.

Clamp Bracket Dimensional Drawing

■

manual tilting type

EFO 40, 50

■

with the Power Trim and Tilt type

EFTO, EPTO 30, 40, 50

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Note

It is recommended to install upper mounting bolts with bolt head at inside surface of transom. Bolts with threaded end at inside surface of transom can cause personal injury.

INSTALLATION

Nut

Bolt

(12mm ×length 105mm)

Washer

(large diameter)

Washer

(small diameter)

ø13

234(9.21”)

39(1.54”)

222(8.74”)

248(9.76”)

26

（

1.02”

）

204(8.03”)

25(0.98”)

64(2.52”)

89(3.50”)

117(4.61”)

102(4.02”)102(4.02”)

117(4.61”)

Top of transom

Nut

Washer

(small diameter)

Washer (large diameter)

Bolt (12mm ×length 105mm)

251

ø12.5

253.5

（

2.0”

）

（

10.0”

）

56

（

2.2”

）

181818

51

327

（

12.9”

）

（

9.9”

）

■

Power Trim and Tilt type

EPTO 115

A propeller must be selected so that the engine rpm measured at wide open throttle while cruising is within the max. operating range; 5,150 to 5,850 rpm Fo r ge nui ne p rope lle rs , refe r to Propeller Table of this manual.

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Notes

1. Apply sealing agent such as silicon sealer between bolts and transom board holes before tightening bolts.

2. Be sure to tighten mounting bolt nuts to speciﬁed torque.

INSTALLATION

Nut

Washer

(small diameter)

Washer (large diameter)

Bolt (12mm ×length 105mm)

251

ø13

0.5”

）

56

（

2.2”

）

254

（

10”

）

327

（

12.9”

）

（

9.9”

）

51（2”

）

Top of

Transom

17.5（0.7”

）

17.5（0.7”

）

17.5（0.7”

）

Notes

The 115 model is supplied with no standard propeller. In other words, it is shipped from the factory without a propeller.

2.

Propeller Selection

30, 40, 50, 115 type

It is recommended that you consult with your authorized dealer for installation adjustment of the rem ote control device.

■

Installation of the Remote Control

Cables (Box side) :

F o l l o w th e in s t r u c t i o n m a n u a l provided with the remote control box.

■

Installation of the Remote Control

Box on your boat :

F o l l o w th e in s t r u c t i o n m a n u a l provided with the remote control box.

■

Connecting the Remote Control

Cable to the engine [40, 50] :

①

Detach the top cowl by turning the

lever.

②

Detach the bracket and set Cable

Harness B and Remote Control Cables. Having fixed the Remote Control Cables to the bracket, tie them to the bottom cowl.

③

Detach the throttle and shift cable joints by removing the R-shaped pins.

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INSTALLATION

3.

Installing the remote control devices

Bracket

Screw

Throttle Cable

Cord Harness B

Shift Cable

Gromment

Clutch

Cable

Throttle Cable

Meter lead wire

Cord

Ass’

y B

Battery Cord

Throttle Cable Joint

R shaped pin

Shift Cable Joint

Washer

R shaped

Be careful not to loop the remote control cables to a diameter of 406 mm (16 inches) or less.

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◎

Screw the tip of the remote control

cable into the cable joint up to approx. 10mm (0.39inch), then lock them with a lock nut. Apply grease to the hole of the cable joint.

④

Move the Remote Control lever Forward, to Neutral and to Reverse to conﬁrm the shift is working, and then set the lever no Neutral.

◎

Double-check that the Remote Control Cables, the throttle cable and shift cable have been

connected correctly. Move the Remote Control Lever Forward until the ﬁrst engaging point (approx 32˚). The cable which is moved first when the lever is turned is a shift cable. Check that

the shift lever is in Neutral and the Free Accel lever is fully closed when the remote control cables have been connected.

⑤

Set the shift arm to the Neutral(N) position and close the advancer arm completely. If the ad vancer ar m does no t co nt act wit h th e st opp er, th e throttle position sensor will be active improperly.

◎

The advancer arm should have contact with the stopper at neutral position of the remote control lever.

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Cable joint

Lock nut

Remote control cable

Approx. 10 mm (0.39 inch)

Free Accel lever

Fully opened

Fully closed

Approx

. 32

°

Shift arm

R

N

F

Advancer arm

Fully closed

Stopper (Throttle fully closed side)

INSTALLATION

⑥

Adjust the cable joint (shift side) so

that the hole meets with the shift arm pin, and lock the cable joint with the nut, and insert the shift arm pin and then secure with a washer and R-shaped pin. Also, adju st th e cab le jo int (throttle side) so that the hole meets with the advancer arm pin, and lock the cable joint with the nut, and insert the advancer arm pin and then secure with a washer and R-shaped pin.

Connecting the Remote Control Cable to the engine [115]

①

Turn the three hook levers fastening

the bottom cowl and then remove the top cowl.

②

Remove the hose clamp fastening the cord grommet. Remove the bolts fastening the cord clamp and then remove the cord clamp and the cord grommet.

③

Detach the throttle and shift cable

Joints by removing the R-shaped pins.

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INSTALLATION

Throttle Cable

Cable Joint

Rod snap

Link rod

R shaped pin Nut

Bolt

Bracket

Screw

Hole for cord ass’y B

Hose clamp Hook lever

Hole for fuel hose

Hole for remote control cable of Shift side

Hole for meter cord ass’y

Hole for trim sender extension cord

Hole for remote control cable of throttle side

Hose clamp

Cord grommet

Bolt

Cord clamp

Free Accel lever

Fully opened

Fully closed

Approx

. 32

°

Move the shift arm Forward, to Neutral and to Reverse to conﬁrm the shift is working, and then set the shift arm to Neutral.

◎

Screw the tip of the remote control cable into the cable joint up to approx.10mm(0.39inch), then lock them with a lock nut. Here, apply grease to the hole of the cable joint.

④

Move the Remote Control lever Forward, to Neutral and to Reverse to conﬁrm the shift is working, and then set the lever no Neutral.

◎

Double-check that the Remote Control Cables, the throttle cable and shift cable have been

connected correctly. Move the Remote Control Lever Forward until the ﬁrst engaging point (approx. 32˚). The cable which is moved first when the lever is turned is a shift cable. Check that the shift lever is in Neutral and the Free Accel lever is fully closed

when the remote control cables have been connected.

⑤

Set the shift arm to the Neutral(N) position and close the advancer arm completely. If the ad vancer ar m does no t co nt act wit h th e st opp er, th e throttle position sensor will be active improperly.

◎

The advancer arm should have contact with the stopper at neutral position of the remote control lever.

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INSTALLATION

R-shaped pin

Washer

Shift cable joint

Shift arm

Throttle cable joint

Cable joint

Lock nut

Remote control cable

Approx. 10 mm (0.39 inch)

Advancer arm

Throttle position sensor

Fully closed

Stopper (Throttle fully closed side)

⑥

Install the hose clamp to the cord grommet. Install the cord clamp.

⑦

Adjust the cable joint (shift side) so

that the hole meets with the shift arm pin, and lock the cable joint with the nut, and insert the shift arm pin and then secure with a washer and R-shaped pin. Also, adju st th e cab le jo int (throttle side) so that the hole meets with the advancer arm pin, and lock the cable joint with the nut, and insert the advancer arm pin and then secure with a washer and R-shaped pin.

Connecting Cords and cable

①

Connect cable harness B and

meter lead wire to cable harness A.

②

Connect the trim sender and the

extension cable trim sensor.

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INSTALLATION

Hose clamp

Bolt

Cord clamp

R-shaped pin

Washer

Shift cable joint

Shift arm

Throttle cable joint

Cable Hamess A

Meter lead wire

Cable Hamess B

Bottom cowl

Trim sender cable

Extension cable trim sender

Do not disconnect the electric couplers while the engine is running, as this will damage the C.D. unit and could result in a serious electric shock.

!



I n s t a l l th e me t e r s s e c u r e l y in t h e d a s h b o a r d w h e r e t h e y ca n be ea s ily rea d and a re n ot exp os ed to water sp la shes. Th e recommended dashboard thickness i s 2 ~ 1 1 m m ( 0 . 0 8 ~ 0 . 4 i n . ) . Fo r dashboards thicker than 11mm(0.4 in.), the fitting plate should be cut accordingly. Be sure to tighten the ﬁtting nuts on the ﬁtting plate evenly.

The dashboard inclination should be 50°~80°

Set the tachometer selector knob to "4p".

Cut holes with 85mm (3.346 in.) diamete r for the tach ome ter and

52.5mm (2.067 in.) for the trim meter.

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INSTALLATION

Fitting plate

Dash board

50°- 80°

12P

6P

4P

Selector

ø85

Tachometer

ø52.5

Trim meter

4. Installing the meters

TOHATSU MD 50B2, MD 40B2, MD 115B2, MD 75C2, MD90C2 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual