Tohatsu MFS 2.5B, MFS 3.5B User Manual

OWNER’S MANUAL

MFS

2.5B

3.5B

OB No.003-11085-3

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

INSTRUCTIONS AND SA FET Y PRECAUTIO NS IN THIS MANUAL CAN RE SULT 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.

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

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

CONTENTS

GENERAL SAFETY INFORMATION

■

SPECIFICATIONS

■

NAMES OF PARTS

■

INSTALLATION

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1. Mounting the outboard motor on boat

■

PRE-OPERATING PREPARATIONS

1.Gasoline and engine oil

2.Break-in

3.ESG

■

ENGINE OPERATION

Before starting

1.Starting

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

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2.Warming up the engine

3.Forward and reverse

4.Stopping

5.Trim angle

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6.Tilt up, tilt down

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

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

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

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

7.Outboard motor positionin tilt 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.Steering friction

2.Throttle grip

INSPECTION AND MAINTENANCE

■

1.Daily inspection

2.Periodic inspection

3.Off-season storage

4.Pre-season check

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

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

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

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

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

5.Motor submerged in water

6.Cold weather precautions

7.Checking after striking underwater object

TROUBLESHOOTING

■

TOOL KIT AND SPARE PARTS

■

OPTIONAL ACCESSORIES

■

PROPELLER TABLE

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

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

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

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

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

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

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

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

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

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INDEX

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

10.TROUBLESHOOTING

11.TOOL KIT AND SPARE PARTS

12.OPTIONAL ACCESSORIES

13.PROPELLER TABLE

DANGER

CAUTION

WARNING

GENERAL SAFETY INFORMATION

WARNING

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

WARNING

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 re comm end t hat o nly an a uthorized serv ice sho p per f orm se rvice 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.

SPECIFICATIONS

2.5B , 3.5B

Item

Overall Length mm (in)

Overall Width mm (in)

Overall Height S·L mm (in)

Transom Height S·L mm (in)

Weight S·L Kg (lb)

Output kW (HP)

Max. Operating Range rpm

Idle Speed in Forward Gear rpm

Idle Speed in Neutral Gear rpm

Engine Type

Number of Cylinder

Bore × Stroke mm (in)

Piston Displacement mL (Cu in)

Exhaust System

Cooling System

Engine Lubrication

Startring System

Ignition System

Spark Plug

Trim Position

Engine Oil mL (ﬂ.oz.)

Gear Oil mL (ﬂ.oz.)

Clutch

Fuel Tank Capacity L (US gal)

Gear Reduction Ratio

: with manual

＊

Speciﬁcations subject to change without notice.

※

MODEL

2.5B 3.5B

690 (27.2)

363 (14.3)

1,026 (40.4) · 1,153 (45.4)

435 (17.1) · 562 (22.1)

18.4 (41) · 19.4 (43)

1.8 (2.5) 2.6 (3.5)

4,500-5,500 5,000-6,000

1,200

1,300

4-Stroke

55 × 36 (2.17 × 1.42)

85.5 (5.2)

Above propeller exhaust

Water cooling

Splashing system

Manual starter

Flywheel Magneto Digital C.D.I

NGK DCPR6E

NMMA FC-W certiﬁed 10W-30 or

API SF, SG, SH, SJ, SL or SM, Approx. 300 (10)

Genuine Gear Oil or API GL5,

SAE #80-90, Approx. 180 (6.1)

Dog clutch system (F-N)

1.0 (0.26) Integral tank

2.15 (13 : 28)

NAMES OF PARTS

2.5B , 3.5B

○

①

Fuel Tank Cap

②

Tilt Handle

③

Top Cowl

④

Cowl Latch

⑤

Cooling Water Check Port

⑥

Steering Adjustment Screw

⑦

Anti Ventilation Plate

⑧

Anode

⑨

Propeller

⑩

Oil Plug (Lower) (Fill)

○

Water Inlet

○

Oil Plug (Upper) (Level)

○

Drive Shaft Housing

○

Thrust Rod

○

Clamp Bracket

○

Clamp Screw

○

Throttle Grip

○

Shift Lever

○

Starter Handle

○

Air Vent Screw

○

Integral Fuel Tank

○

Choke Knob Stop Switch Tilt Stopper Engine Oil Filter Cap Engine Oil Drain Screw Engine Oil Level Gauge Air Vent Screw Fuel Cock

Center of Boat

CAUTION

WARNING

INSTALLATION

1. Mounting the outboard motor on boat

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.

Position ... Above keel line

Set engine at center of boat.

Boat Transom

Transom matching

Be sure that the anti ventilation plate of the outboard motor is below the water surface. If the above condition cannot be met due to the shape of the bottom of your boat, please consult your authorized dealer.

Bottom of hull

30-50mm (1.2-2”)

Anti Ventilation Plate

To attach the outboard motor to the boat, tighten the clamp screws by turning their handles. Al so, use the b olts to secure th e outboard motor brackets on transom board. Secure the outboard motor with a rope to prevent loss overboard.

Note

A rope is not included in the standard accessories.

Clamp screw

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 the engine to such conditions for extended periods can lead to severe engine damage.

INSTALLATION

WARNING

CAUTION

If the length of security line being used is long enough to allow the outboard to disengage off the boat transom but is too short to not allow the outboard to submerge behind the boat and stop running, the outboard could continue running and propel itself back into the boat with the propeller rotating under power. This exposes the occupants to serious injury or death.

Mounting the outboard motor

●

without following this manual can lead to unsafe conditions such as poor maneuverability, lack of control or ﬁre.

Loose clamp screws and/or

●

mounting bolts can lead to release off 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 fasteners for tightness from time to time.

Be sure to use outboard mounting

●

fasteners included in 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.

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.

Notes

1. Apply sealing agent such as silicone sealed between bolts and transom board holes before tightening bolts.

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

CAUTION

DANGER

PRE-OPERATING PREPARATIONS

Consult an authorized dealer for details on handling gasoline, if necessary.

Gasoline and its vapors are very ﬂammable and can be explosive.

When carrying a fuel tank containing gasoline:

Close the air vent screw of fuel tank cap, or

●

gasoline vapor will be emitted through the air vent screw, creating a ﬁre hazard. Do not smoke.

●

When or before refueling:

Stop the engine, and do not start the

●

engine during refueling. Do not smoke.

●

Be careful not to overﬁll fuel tank. Wipe up

●

any spilled gasoline immediately.

When or before cleaning the gasoline tank:

Dismount fuel tank from the boat.

●

Place the fuel tank away from every source

●

of ignition, such as sparks or open ﬂames. Do the work outdoors or in a well ventilated

●

area. Wipe off gasoline well immediately if spilt.

●

After cleaning gasoline tank:

Wipe off gasoline well immediately if spilt.

●

If the fuel tank is disassembled for cleaning,

●

reassemble carefully. Imperfect assembly may cause a fuel leak, possibly leading to ﬁre or explosion. Dispose aged or contaminated gasoline in

●

accordance with local regulations.

Recommended gasoline types

Use of low-quality gasoline results in a short engine life as well as star ting difﬁculties and other engine problems. We recommend use for Fuel stabilizer.

Use of unleaded gasoline

UNITED STATES AND CANADA:

Use a major brand of automotive unleaded gasoline with a minimum posted octane rating of 87. Mid-grade automotive gasoline that contain fuel injector cleaner are preferred for added internal engine cleanliness. Leaded gasoline is not recommended.

INTERNATIONAL :

of automotive unleaded gasoline with a minimum posted octane rating of 91RON. Automotive gasoline that contain fuel injector cleaner are preferred for added internal engin e cle anlines s. Le aded gasoline is acceptable in areas where unleaded gasoline is not available.

Use a major brand

Use of alcohol free gasoline

Use of gasoline containing alcohol can cause engine starting and/or operating difﬁculties, wear of and damages to engine parts, and deterioration of chemical par ts, which may lead to shortening of your outboard motor’s life.

Note

The adverse effect caused by the alcohol content

is more severe with methanol than with ethanol.

TOHATSU recommend the use of gasoline if its ethanol content is less than 10% or methanol content is less than 5%, only in case alcohol free gasoline is not available. Th e alcohol comp onen t of the gas oline absorbs moisture from the air, which may disturb regular fuel flow in the fuel system,

CAUTION

WARNING

PRE-OPERATING PREPARATIONS

and also accelerate rusting of engine parts. Mixing of the moisture in the engine oil can also deteriorate the properties of the lubricant.

If the use of gasoline containing alcohol is inevitab le, or presence of al c ohol is susp ected in the gasoline, it is strongly recommended to add a filter that has water separating capability, and check the fuel syste m for leak s and mechani cal p ar ts fo r corrosion and abnor m al wear more frequently. And, in case any of such abnormalit y is found, discontinue the use of such gasoline and contact our dealer immediately. Damages resulting from the use of gasolines that contain alcohol are not covered under the limited warranty. Fuel tank capacity : 25 liters (6.6 U.S. gal)---for 30, 40, 50 Fu e l Tan k : Wh e n usi n g a f i xe d fu el ta nk in place of genuin e fue l tan k, it is reco m men d e d to se l ect a on e w i t h a structure facilitating interior cleaning.

Do not ﬁll the fuel tank over capacity. The rise of gasoline temperature may cause gasoline to expand which, if overﬁlled, may leak through air vent screw when it is open. Leaking gasoline is a dangerous ﬁre hazard.

prolonged engine life. Use NMMA FC-W certified 4-stroke engine oil below.

10W-30: is recommended for use in all temperature. You can also use oils that carry the API rating of SF, SG, SH, SJ, SL, or SM. Select the appropriate viscosity, based on atmospheric temperature, from the chart below.

ENGINE

OIL

-30

-22

-20

-4

10W−40

10W−30

-10 14

Atmospheric temp.

20 68

The engine oil is drained for shipping from the factory. Be sure to ﬁll the engine to the proper level before starting engine. (To properly ﬁll the engine with oil follow the instructions in section 9 of this manual)

Note

Use of engine oils that do not meet these requirements will result in reduced engine life, and other engine problems.

˚C ˚F

2. Recommended engine oil

Us e onl y hig h qu a l i t y 4- s t r o k e engine oil to insure performance and

PRE-OPERATING PREPARATIONS

DANGER

CAUTION

3. Break-In

Your new outboard motor and lower unit require break-in for the moving c o m p o n e n ts a c c o r d i n g to t h e conditions described in the following time table.

1-10min 10min-2hrs 2-3hrs 3-10hrs After 10hrs

Throttle Position Idle

Speed

Less than 1/2

throttle

Approx.

3,000 rpm max

Note

Operating the outboard motor without break-in can shorten service life of the product. If any abnormality is experienced during the break-in:

Discontinue the operation

●

immediately.

Have the dealer check the product

●

and take proper action(s) if necessary.

Less than 3/4

throttle

Full throttle run

allowed for 1 min

every 10 min

3/4 throttle

Approx.

4,000 rpm.

Full throttle run

allowed for 2 min

every 10 min

Full throttle

available

Proper break-in allows outboard motor to deliver it full performance for longer service life.

Do not operate the outboard motor in closed area or area with no forced ventilation. Exhaust gas emitted by this outboard motor contains carbon monoxide that will cause death if inhaled continuously. Inhaling the gas initially causes symptoms such as feeling of sickness, drowsiness and headache. During operation of the outboard motor:

Keep peripheral area well ventilated.

●

Always attempt to stay on the

●

windward side of emission.

+ 36 hidden pages

Tohatsu MFS 2.5B, MFS 3.5B User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual