Tohatsu MFS 4B Manual

OWNER’S

MANUAL

MFS4B 5B 6B

OB No.003-11059-6

!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 © 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

CONTENTS

■GENERAL SAFETY INFORMATION 8

■SPECIFICATIONS 10

■NAMES OF PARTS 11

■INSTALLATION 12

1.Mounting the outboard motor on boat 12

■PRE-OPERATING PREPARATIONS 14 1.Gasoline and engine oil 14 2.Break-in 16 3.Engine oil warning lamp 17 4.ESG 17

■ENGINE OPERATION 18 Before starting 18 1.Starting 18 2.Warming up the engine 21 3.Forward and reverse 22 4.Stopping 23 5.Trim angle 24

6.Tilt up, tilt down and shallow water operation 25

7.Shallow water operation 26

■REMOVING AND CARRYING THE OUTBOARD MOTOR 28

1.Removing the outboard motor 28 2.Carrying the outboard motor 28 3.Storing the outboard motor 28

■TRAILERING 29

■ADJUSTMENT 30 1.Steering friction 30 2.Throttle grip 30 3.Reverse lock 30

■INSPECTION AND MAINTENANCE 31 1.Daily inspection 32 2.Periodic inspection 37 3.Off-season storage 41 4.Pre-season check 42 5.Motor submerged in water 43 6.Cold weather precautions 43

7.Checking after striking underwater object 44

■TROUBLESHOOTING 45

■TOOL KIT AND SPARE PARTS 48

■OPTIONAL ACCESSORIES 49

■PROPELLER TABLE 50

7

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

1

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12

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GENERAL SAFETY INFORMATION

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.

! DANGER

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

! WARNING

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

! CAUTION

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.

! 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 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.

! 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.

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.

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.

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SPECIFICATIONS

MF , EF , EP

	MODEL	4B(D) 5B(D) M6B(D)			5B(S) 6B(S)
Item		(Integral Tank)			(Separate Tank)
Overall Length	mm (in)		680 (26.8)
Overall Width	mm (in)		325 (12.8)
	S mm (in)	1,073 (42.2)			1,020 (40.2)
Overall Height S·L·UL	L mm (in)	1,200 (47.2)			1,147 (45.2)
	UL mm (in)	1,327 (52.2)			1,274 (50.2)
Transom Height S·L·UL	mm (in)	435 (17.1) · 562 (22.1) · 689 (27.1)
	S Kg (lb)	26 (57)			25 (55)
Weight	L Kg (lb)	27 (59)			26 (57)
	UL Kg (lb)	28 (61)			27 (59)
Output	kW (Hp)	4B : 2.9 (4)	5B : 3.7 (5)		6B : 4.4 (6)
Max. Operating Range	rpm	4B & 5B : 4,500 - 5,500		6B :5,000 - 6,000
Idle Speed in Forward Gear	rpm		1,100
Idle Speed in Neutral Gear	rpm		1,300
Engine Type			4-Stroke
Number of Cylinder			1
Bore × Stroke	mm (in)	59 × 45 (2.32 × 1.77)
Piston Displacement	mL (Cu in)		123 (7.5)
Exhaust System		Through hub exhaust
Cooling System			Water cooling
Engine Lubrication			Trochoid pump
Startring System			Manual Starter
Ignition System		Flywheel Magneto C.D. ignition
Spark Plug			NGK DCPR6E
Trim Position			6
Engine Oil		API SF, SG, SH or SJ
		FCW 10W-30/40, Approx. 450 (15.2)
Gear Oil		Genuine Gear Oil or API GL5,
		SAE #80-90, Approx. 195mL
Fuel Tank Capacity	L (US gal)	1.3 (0.34) Integral			12 (3.17) Separate
Gear Reduction Ratio			2.15 (13 : 28)
In case of dual fuel tank system, use it together with 12L separate tank.

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NAMES OF PARTS

4B , 5B , 6B

		○
		20
		○
○	18	19
		○
1	○	21		23
○				○
2	○
	17
○
3	○			○
○	16			24
4	15	○
○5	○	22	○		○
	○		25		25
6	14
	○
○	13		Integral fuel tank	Dual fuel tank
○	○
7	12			○
			26		30
			○	31
8					○
○	○				○
	11				29
9	○				○
○
	10		○		28
			27
	32
	○
		33
		○
		34
		○

	Tilt Handle	○Clamp Bracket	○Fuel Tank
	Top Cowl	14	27
		○Clamp Screw	○Fuel Pick up Elbow
	Lower Motor Cover	15	28
		○Throttle Grip	○Fuel Connector
	Cooling Water Check Port	16	29
		○Shift Lever	○Air Vent Screw
		17	30
Tilt Lever		○Starter Handle	○Fuel Tank Cap
Steering Adjustment Screw		18	31
		○Choke Knob	○Engine Oil Filter Cap
Anode		19	32
		○Stop Switch	○Spark Plug
Anti Ventilation Plate		20	33
		○Fuel Connector	○Engine Oil Drain Screw
Propeller		21	34
		○Warning Lamp
Oil Plug (Lower) (Fill)		22
		○Air Vent Screw
○Water Inlet		23
		○Fuel Connector
11		24
○Oil Plug (Upper) (Level)		○Fuel Cock
12		25
○Thrust Rod		○Primer Bulb
13		26

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INSTALLATION

1. Mounting the outboard motor on boat

				! WARNING
	1
				Most boats are rated and certified
				in terms of their maximum allowable
	2
				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.
	3
				Do not operate the outboard motor until it
				has been securely mounted on the boat
				in accordance with the instructions below.
	4
				Position ... Above keel line
	5			Set engine at center of boat.
				Center of Boat
	6
	7			Boat Transom
	8			Transom matching
			Be sure that the anti ventilation plate of
	9
			the outboard motor is below the water
			surface when running with the throttle
			wide open.
	10
			If the above condition cannot be met
			due to the shape of the bottom of your
			boat, please consult your authorized
	11
			dealer.
	12			Bottom of hull
				30-50mm
				(1.2-2”)

Anti Ventilation Plate

!CAUTION

●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 production of 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.

To attach the outboard motor to the boat, tighten the clamp screws by turning their handles.

Secure the outboard motor with a rope to prevent loss overboard.

Note

The rope is not included in the standard accessories.

: Option

Clamp Screw

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 13

	! WARNING
	●Mounting outboard motor without
	following this manual can lead to unsafe
				1
	conditions such as poor maneuverability,
	going out of control or fire disaster.
	●Loose clamp screws and/or mounting
				2
	bolts can lead to coming off or
	displacement of outboard motor,
	possibly going out of control or causing
	serious personal injury. Be sure that
				3
	fasteners are tightened to the specified
	torque (30 Nm (3.0kgf)13ft·lb). Check
	fasteners for tightness from time to time.
				4
	●Be sure to use outboard mounting
	fasteners included in outboard motor
	package delivered or their equivalents
	in terms of size, material, quality and			5
	strength.
	Tighten fasteners to the specified torque
	(30 Nm (3.0kgf)13ft·lb). Test cruise
				6
	to check if fasteners are tightened
	securely.
	●Outboard motor mounting must be
	performed by trained service person(s)			7
	using lift or hoist with sufficient capacity.
				8
				9
				10
				11

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PRE-OPERATING PREPARATIONS

! DANGER

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.

1.Recommended gasoline types

! CAUTION

Use of low-quality gasoline results in a short engine life as well as starting 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 : Use a major brand of automotive unleaded gasoline with a minimum posted octane rating of 91RON. Automotive gasoline that contain fuel injector cleaner are preferred for added internal engine cleanliness. Leaded gasoline is acceptable in areas where unleaded gasoline is not available.

Use of alcohol free gasoline

! CAUTION

Use of gasoline containing alcohol can cause engine starting and/or operating difficulties, wear of and damages to engine parts, and deterioration of chemical parts, 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.

The alcohol component of the gasoline absorbs moisture from the air, which may disturb regular fuel flow in the fuel system,

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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 inevitable, or presence of alcohol is suspected in the gasoline, it is strongly recommended to add a filter that has water separating capability, and check the fuel system for leaks and mechanical parts for corrosion and abnormal wear more frequently.

And, in case any of such abnormality 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

Fuel Tank : When using a fixed fuel tank in place of genuine fuel tank, it is recommended to select a one with a structure facilitating interior cleaning.

! WARNING

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.

2. Recommended engine oil

Use only high quality 4- stroke engine oil to insure performance and prolonged engine life.

Use NMMA FC-W certified 4-stroke

PRE-OPERATING PREPARATIONS 15

engine oil below.

10W-30: is recommended for use in all temperature.

25W-40: may be used at temperatures															1
above 4˚C (40˚F).
															2
You can also use oils that carry the
API rating of SF, SG, SH, SJ, SL, or
SM. Select the appropriate viscosity,
															3
based on atmospheric temperature,
from the chart below.
															4
						20W−40,		20W−50
						15W−40, 15W−50
ENGINE															5
OIL
					10W−40, 10W−50
															6
					10W−30
-30 -20			-10		0 10 20 30 40							˚C
-22 -4 14					32 50 68 86 96							˚F
															7
				Atmospheric temp.

! CAUTION
			8
The engine oil is drained for shipping
from the factory. Be sure to fill the
			9
engine to the proper level before
starting engine. (To properly fill the
engine with oil follow the instructions in
section 9 of this manual)			10
Note			11

Use of engine oils that do not meet
these requirements will result in		12
reduced engine life, and other engine
problems.
		13

16 PRE-OPERATING PREPARATIONS

3. Break-in

			Your new outboard motor and lower
								!	CAUTION
1
			unit require break-in for the moving
			c o m p o n e n t s		a c c o rd i n g t o t h e			Operating the outboard motor without
			conditions described in the following					break-in can shorten service life of the
2
			time table.					product.
								If any abnormality is experienced
								during the break-in:
3								● Discontinue the operation
								immediately.
								● Have the dealer check the product
								and take proper action(s) if
4
								necessary.
5
					1-10min	10min-2hrs		2-3hrs	3-10hrs		After 10hrs
						Less than 1/2	Less than 3/4				Full throttle
6			Throttle Position		Idle				3/4 throttle
						throttle		throttle			available
7									Approx.
						Approx.	Full throttle run		4,000 rpm.
			Speed				allowed for 1 min		Full throttle run
						3,000 rpm max
8							every 10 min		allowed for 2 min
									every 10 min
9			Note					!	DANGER
			Proper break-in allows outboard
								Do not operate the outboard motor
			motor to deliver it full performance for					in closed area or area with no forced
10
			longer service life.					ventilation.
								Exhaust gas emitted by this outboard
								motor contains carbon monoxide that
11
								will cause death if inhaled continuously.
								Inhaling the gas initially causes
								symptoms such as feeling of sickness,
12								drowsiness and headache.
								During operation of the outboard motor:
								● Keep peripheral area well ventilated.
								● Always attempt to stay on the
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								windward side of emission.
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