Tohatsu MD 115A2, MD 30B2 User Manual

OWNER’S

MANUAL

MD

30B2 40B2 50B2

115A2

OB No.003-11075-9

READ THIS MANUAL BEFORE USING THE OUTBOARD MOTOR. FAILURE TO FOLLOW THE

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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 © 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.

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

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

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

5.Checking after striking underwater object

6.If the engine becomes submerged in water

7.Precautions in cold weather

10

TROUBLESHOOTING

■

11

TOOL KIT AND SPARE PARTS

■

12

OPTIONAL ACCESSORIES

■

13

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

INDEX

7

GENERAL SAFETY INFORMATION

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

1

2

3

4

5

6

7

8

9

10.TROUBLESHOOTING

11.TOOL KIT AND SPARE PARTS

12.OPTIONAL ACCESSORIES

13.PROPELLER TABLE

10

11

12

13

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GENERAL SAFETY INFORMATION

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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.

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

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

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

Note

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

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.

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

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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.

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.

SERVICING, REPLACEMENT PARTS & LUBRICANTS

We recommend t hat only an aut horized ser vice shop p erfor 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.

1

2

3

4

5

6

7

8

9

10

11

12

13

10

SPECIFICATIONS

30B2 , 40B2

MODEL 30B2 40B2

Item EPTO EFTO EFO

Overall Length mm (in)

Overall Width mm (in)

Overall Height S·L·UL mm (in)

Transom Height S·L·UL

Weight

Output kW (Hp)

Max. Operating Range rpm

Engine Type

Number of Cylinder

Bore ×Stroke mm (in)

Piston Displacement mL (Cu in)

Exhaust System

Cooling System

Engine Lubrication

Starting System

Ignition System

Spark Plug

Alternator

Trim Position

Engine Oil

Gear Oil

Fuel Tank Capacity L (US gal)

Engine Oil Capacity L (US gal)

Gear Reduction Ratio

Fuel

This speciﬁcations might change without a previous notice.

※

mm (in)

S kg (lb)

L kg (lb)

UL kg (lb)

630 (24.8) 1,120 (44.1)

345 (13.6) 384 (15.1)

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

403 (15.9) · 530 (20.9) · 657 (25.9)

- - -

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

- - -

22.1 (30) 29.4 (40)

4,750 - 5,750

Direct fuel injection

3

68 × 64 (2.68 × 2.52)

697 (42.5)

Through hub exhaust

Water cooling

Oil injection

Electric starter motor

Inductive Ignition

NGK IZFR6J

12V,280W (Max.)

4 6

Genuine Motor Oil or recommended one

Genuine Gear Oil or API GL5,

SAE #80 to #90, approx. 500mL

25 (6.6)

Approx. 2.0 (0.53)

1.85 (13 : 24)

Unleaded regular gasoline : Pump posted 87 Octane

(research octane rating of 91)

14

SPECIFICATIONS

50B2

MODEL 50B2

Item EPTO EFTO EFO

Overall Length mm (in)

Overall Width mm (in)

Overall Height S·L·UL mm (in)

Transom Height S·L·UL

Weight

Output kW (Hp)

Max. Operating Range rpm

Engine Type

Number of Cylinder

Bore ×Stroke mm (in)

Piston Displacement mL (Cu in)

Exhaust System

Cooling System

Engine Lubrication

Starting System

Ignition System

Spark Plug

Alternator

Trim Position

Engine Oil

Gear Oil

Fuel Tank Capacity L (US gal)

Engine Oil Capacity L (US gal)

Gear Reduction Ratio

Fuel

This speciﬁcations might change without a previous notice.

※

mm (in)

S kg (lb)

L kg (lb)

UL kg (lb)

630 (24.8) 1,120 (44.1)

345 (13.6) 384 (15.1)

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

403 (15.9) · 530 (20.9) · 657 (25.9)

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

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

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

29.4 (40) 36.8 (50)

5,150 - 5,850

Direct fuel injection

3

68 × 64 (2.68 × 2.52)

697 (42.5)

Through hub exhaust

Water cooling

Oil injection

Electric starter motor

Inductive Ignition

NGK IZFR6J

12V,280W (Max.)

4 6

Genuine Motor Oil or recommended one

Genuine Gear Oil or API GL5,

SAE #80 to #90, approx. 500mL

25 (6.6)

Approx. 2.0 (0.53)

1.85 (13 : 24)

Unleaded regular gasoline : Pump posted 87 Octane

(research octane rating of 91)

11

1

2

3

4

5

6

7

8

9

10

11

12

13

1

2

3

4

5

6

7

8

9

10

11

12

13

12

SPECIFICATIONS

W50B2

MODEL W50B2

Item EPTO EFTO

Overall Length mm (in)

Overall Width mm (in)

Overall Height L·UL mm (in)

Transom Height L·UL

Weight

Output kW (Hp)

Max. Operating Range rpm

Engine Type

Number of Cylinder

Bore ×Stroke mm (in)

Piston Displacement mL (Cu in)

Exhaust System

Cooling System

Engine Lubrication

Starting System

Ignition System

Spark Plug

Alternator

Trim Position

Engine Oil

Gear Oil

Fuel Tank Capacity L (US gal)

Engine Oil Capacity L (US gal)

Gear Reduction Ratio

Fuel

This speciﬁcations might change without a previous notice.

※

mm (in)

L kg (lb)

UL kg (lb)

630 (24.8) 1,120 (44.1)

345 (13.6) 384 (15.1)

1,415 (55.7) · 1,542 (60.7)

550 (21.7) · 677 (26.7)

100.5 (222) 103.5 (228)

101.5 (224) 104.5 (230)

36.8 (50)

5,150 - 5,850

Direct fuel injection

3

68 × 64 (2.68 × 2.52)

697 (42.5)

Through hub exhaust

Water cooling

Oil injection

Electric starter motor

Inductive Ignition

NGK IZFR6J

12V,280W (Max)

4

Genuine Motor Oil or recommendedone

Genuine Gear Oil or API GL5,

SAE #80 to #90, approx. 700mL

25 (6.6)

Approx. 2.0 (0.53)

1.92 (12 : 23)

Unleaded regular gasoline : Pump posted 87 Octane

(research octane rating of 91)

14

115A2

MODEL 115A2

Item EPTO

Overall Length mm (in)

Overall Width mm (in)

Overall Height L·UL mm (in)

Transom Height L·UL

Weight

Output kW (Hp)

Max. Operating Range rpm

Engine Type

Number of Cylinder

×

Bore

Stroke mm (in)

Piston Displacement mL (Cu in)

Exhaust System

Cooling System

Engine Lubrication

Starting System

Ignition System

Spark Plug

Alternator

Trim Position

Engine Oil

Gear Oil

Fuel Tank Capacity L (US gal)

Engine Oil Capacity L (US gal)

Gear Reduction Ratio

Fuel

This speciﬁcations might change without a previous notice.

※

mm (in)

L·UL kg (lb)

Unleaded regular gasoline : Pump posted 87 Octane

Genuine Motor Oil or recommended one

SAE #80 to #90, approx. 900mL

800 (31.5)

495 (19.5)

1,640 (64.6) · 1,767 (69.6)

517 (20.4) · 644 (25.4)

178 (392) · 181 (399)

84.6 (115)

5,150 - 5,850

Direct fuel injection

88 × 72.7 (3.46 × 2.86)

1,768 (107.9)

Through hub exhaust

Water cooling

Oil injection

Electric starter motor

Inductive ignition

NGK IZFR5J

12V,490W (Max.)

Genuine Gear Oil or API GL5,

Approx. 6.7 (1.77)

2.0 (13:26)

(research octane rating of 91)

4

2

-

SPECIFICATIONS

13

1

2

3

4

5

6

7

8

9

10

11

12

13

1

○

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

○

13

○

14

○

15

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16

○

17

○

18

○

19

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20

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21

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22

○

12

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4

○

5

○

6

○

7

2

3

4

5

6

14

NAMES OF PARTS

EFO / 40B2 , 50B2

10

11

12

13

14

7

8

9

①

Tilt Handle

②

Top Cowl

③

Hook Lever

④

Water Check Port

⑤

Reverse Lock Lever

⑥

Water Plug

⑦

Anti-ventilation Plate

⑧

Trim Tab

⑨

Propeller

⑩

Oil Plug (lower)

11

○

Water Inlet

12

○

Oil Plug(upper)

13

○

Clamp Bracket

14

○

Thrust Rod

15

○

Clamp Screw

16

○

Throttle Grip

17

○

Stop Switch

18

○

Shift Lever

19

○

Anode

20

○

Pilot Lamp

21

○

Main Switch

22

○

Battery Cords

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

○

1

○

2

○

3

○

8

○

9

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10

○

10

○

11

○

13

○

14

○

15

○

16

○

17

○

18

○

24

○

22

○

19

○

20

○

23

○

21

○

12

○

4

○

5

○

6

○6○

12

○

7

[W50]

NAMES OF PARTS

15

1

2

3

4

5

6

7

①

Tilt Handle

②

Top Cowl

③

Hook Lever

④

Water Check Port

⑤

Tilt Stopper

⑥

Water Plug

⑦

Anti-ventilation Plate

⑧

Trim Tab

⑨

Propeller

⑩

Oil Plug (lower)

11

○

Water Inlet

12

○

Oil Plug(upper)

13

○

Clamp Bracket

14

○

Thrust Rod

15

○

Clamp Screw

16

○

Throttle Grip

17

○

Shift Lever

18

○

Stop Switch

19

○

Pilot Lamp

20

○

Main Switch

21

○

Battery Cords

22

○

Power Trim & Tilt

23

○

Anode

24

○

Power Trim & Tilt Switch

8

9

10

11

12

13

1

○

1

○

2

○

3

○

8

○

9

○

10

○

11

○

13

○

14

○

15

○

16

○

17

○

18

○

19

○

20

○

21

○

12

○

4

○

5

○

6

○

7

○

10

○6○

12

[W50]

2

3

4

5

6

NAMES OF PARTS

16

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

10

11

12

13

14

7

8

9

①

Tilt Handle

②

Top Cowl

③

Hook Lever

④

Water Check Port

⑤

Tilt Stopper

⑥

Water Plug

⑦

Anti-ventilation Plate

⑧

Trim Tab

⑨

Propeller

⑩

Oil Plug (lower)

11

○

Water Inlet

12

○

Oil Plug(upper)

13

○

Clamp Bracket

14

○

Thrust Rod

15

○

Clamp Screw

16

○

Filler Lid

17

○

Fuel Connector

18

○

Power Trim & Tilt Switch

19

○

Battery Cords

20

○

Power Trim & Tilt

21

○

Anode

EPTO / 115A2

○

1

○

2

○

3

○

3

○

8

○

9

○

10

○

11

○

13

○

14

○

15

○

16

○

17

○

18

○

19

○

12

○

4

○

5

○

6

○

7

○

27

○

30

○

29

○

28

○

31

○

32

NAMES OF PARTS

17

1

2

3

4

5

6

7

8

20

○

Remote Control Box

21

○

Remote Control Lever

22

○

Power Trim & Tilt Switch

23

○

Free Accel Lever

24

○

Main Switch

25

○

Harness B

26

○

Stop Switch

27

○

Fuel Tank

28

○

Air Vent Screw

29

○

Fuel Connector

30

○

Primer Bulb

Note

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

31

○

Tachometer

32

○

Trim Meter

9

10

11

12

13

18

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A A

40 - 90 : 470 - 660mm

(18.5 - 26.0 in)

115 : 700 - 890mm

(27.6 - 35.0 in)

INSTALLATION

1. Mounting the outboard motor on boat

1

Most boats are rated and certiﬁed in terms of their maximum allowable

2

3

4

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.

5

Consult your authorized dealer to

6

7

8

9

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

Installation

Single-engine Installation

■

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

10

11

12

Note

Twin-engine Installation

■

W h e n in s t al li ng two o u t b oa rd engines, be sure to keep an interval of 4 70~660mm (for 40,50,70 a nd 90 models) or 700~890mm (for 115 model) between the two.

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.

13

14

INSTALLATION

Anti-ventilation Plate

10~30mm (0.4~1.2 in.)

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19

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 t hat an ti venti la tion p la te 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.

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.

If the he igh t d iff ere nce exce eds 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 beforehand by re f e r r ing to t h e dimensional drawing.

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.

1

2

3

4

5

6

7

8

9

10

11

12

13

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”

）

20

Clamp Bracket Dimensional Drawing

1

2

3

4

5

6

7

8

9

manual tilting type

■

EFO 40, 50

with the Power Trim and Tilt type

■

EFTO, EPTO 30, 40, 50

10

11

12

13

14

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.

Power Trim and Tilt type

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”

）

■

EPTO 115

INSTALLATION

Propeller Selection

2.

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 For ge nuin e prope l lers , refe r to Propeller Table of this manual.

Notes

21

1

2

3

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.

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

4

5

6

7

8

9

10

11

12

13

1

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

!



2

3

4

5

INSTALLATION

22

3.

Installing the remote control devices

30, 40, 50, 115 type

It is recommended that you consult with your authorized dealer for installation ad justm ent o f t he rem ote co ntrol device.

Installation of the Remote Control

■

Cables (Box side) :

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

Installation of the Remote Control

■

Box on your boat :

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

Detach the bracket and set Cable

②

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

6

■

①

7

8

9

10

11

12

13

14

Connecting the Remote Control

Cable to the engine [40, 50] :

Detach the top cowl by turning the

lever.

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

Detach the throttle and shift cable

③

joints by removing the R-shaped pins.

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

23

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.

Move the Remote Control lever

④

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

Double-c he ck that the Remote

◎

Control Cables, the throttle cable and shift cable have been 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

connected

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

Set the shift arm to the Neutral(N)

⑤

position and close the advancer arm completely. If the adva nce r a r m d oes not con t act w ith th e stopp e r, the th ro ttle pos ition sensor will be active improperly.

The advancer arm should have

◎

contact with the stopper at neutral position of the remote control lever.

1

2

3

4

5

6

7

8

9

10

11

12

13

1

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

2

3

4

5

6

INSTALLATION

24

Adjust the cable joint (shift side) so

⑥

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, ad jus t the cable join t (throt tle side) so that the hole meets with the advancer ar m 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]

Turn the three hook levers fastening

①

the bottom cowl and then remove the top cowl.

Remove the hose clamp fastening

②

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

7

8

9

10

11

12

13

14

Detach the throttle and shift cable

③

Joints by removing the R-shaped pins.

Free Accel lever

Fully opened

Fully closed

Approx

. 32

°

Move the shift ar m Forward, to

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)

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.

Move the Remote Control lever

④

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

Double-c he ck that the Remote

◎

Control Cables, the throttle cable and shift cable have been 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

connected

INSTALLATION

when the remote control cables have been connected.

Set the shift arm to the Neutral(N)

⑤

position and close the advancer arm completely. If the adva nce r a r m d oes not con t act w ith th e stopp e r, the th ro ttle pos ition sensor will be active improperly.

The advancer arm should have

◎

contact with the stopper at neutral position of the remote control lever.

25

1

2

3

4

5

6

7

8

9

10

11

12

13

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

!



26

⑥

1

2

3

4

5

⑦

6

7

8

9

10

11

12

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

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, ad jus t the cable join t (throt tle side) so that the hole meets with the advancer ar m 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

Co nnect cable har ness B a nd

①

meter lead wire to cable harness A.

Connect the trim sender and the

②

extension cable trim sensor.

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.

13

14

Fitting plate

Dash board

50°- 80°

12P

6P

4P

Selector

ø85

Tachometer

ø52.5

Trim meter

4. Installing the meters

I n s t al l th e m e t e r s se c u re l y i n t h e d a s h b o a r d w h e r e t h e y can be ea s i ly r e ad a n d are no t exp osed to water spl ash es. Th e recommended dashboard thickness i s 2 ~ 1 1 m m ( 0. 08 ~0 .4 i n .) . F o 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.

INSTALLATION

Cut ho les with 85mm (3.3 46 in.) diameter for t he tach ome ter a nd

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

27

1

2

3

4

5

6

The dashboard inclination should be 50°~80°

Set the tachometer selector knob to "4p".

7

8

9

10

11

12

13

Tohatsu MD 115A2, MD 30B2 User Manual

YOUR TOHATSU OUTBOARD MOTOR

CONTENTS

INDEX

GENERAL SAFETY INFORMATION

SPECIFICATIONS

NAMES OF PARTS

INSTALLATION