OWNER’S

MANUAL

M 60C
M 70C
M 70CX
M 90A2
M 115A2
M 140A2
OB No.00311039EAH1
 ENOM00001-0
READ THIS MANUAL BEFORE USING THE OUTBOARD MOTOR. FAILURE TO FOLLOW THE
INSTRUCTIONS AND SAFETY PRECAUTIONS IN THIS MANUAL CAN RESULT IN SERIOUS
INJURY OR DEATH. KEEP THIS MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE.

Copyright © 2018 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.
 3

YOUR TOHATSU OUTBOARD MOTOR

ENOM00006-A
To You, Our Customer
Thank you for selecting a TOHATSU outboard motor. You are now the proud owner of an
excellent outboard motor that will service you for many years to come.
This manual should be read in its entirety and the inspection and maintenance procedures
described later in this manual should be followed carefully. Should a problem arise with the
outboard motor, please follow the troubleshooting procedures listed at the end of this
manual. If the problem persists, contact an authorized TOHATSU service shop or dealer.

All information in this manual is based on the latest product information available at the
time of approval for printing.
Tohatsu Corporation reserves the right to make changes at any time without notice and
without incurring any obligation.

Please always keep this manual together with the outboard motor as a reference to every-
one who uses the outboard motor. If the outboard motor is resold, make sure the manual
is passed on to the next owner.

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

ENOM00003-0
PRE-DELIVERY CHECK
Be sure that the product has been checked by an authorized TOHATSU dealer before you
take delivery.
4

ENOM00005-A
Serial Number
In the space below, please record the outboard motor's serial number. The serial number
will be needed when ordering parts, and when making technical or warranty inquiries.

Serial Number:

60/70

ENOF01300-1 ENOF02371-1

90/115/140

ENOF02373-1

Serial Number: Date of purchase:

 5

ENOM00007-0
NOTICE: DANGER/WARNING/CAUTION/Note
Before installing, operating or otherwise handling your outboard motor, be sure to thor-
oughly read and understand this Owner's Manual and carefully follow all of the instruc-
tions. Of particular importance is information preceded by the words “DANGER,”
“WARNING,” “CAUTION,” and “Note.” Always pay special attention to such information to
ensure safe operation of the outboard motor at all times.
ENOW00001-0

DANGER
Failure to observe will result in severe personal injury or death, and possibly property dam-
age.

ENOW00002-0

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

ENOW00003-0

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

ENON00001-0
Note
This instruction provides special information to facilitate the use or maintenance of the outboard
motor or to clarify important points.
 CONTENTS
1. GENERAL SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3. PARTS NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4. LABEL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1. Mounting the outboard motor on boat . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2. Remote control device installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3. Drag link installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4. Battery installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5. Tiller handle installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6. Propeller installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6. PRE-OPERATING PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1. Fuel handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2. Engine oil recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3. Fuel filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4. Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5. Warning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7. ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1. Engine oil feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2. Fuel feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3. Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4. Warming up the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5. Forward, reverse, and acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6. Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7. Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8. Trim angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9. Tilt up and down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10.Shallow water operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8. REMOVING AND CARRYING THE OUTBOARD MOTOR. . . . . . . . . . . . . . 63
1. Removing the outboard motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2. Carrying the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3. Trailering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9. ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1. Throttle grip friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2. Remote control lever friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3. Trim tab adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
10. INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1. Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2. Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3. Off-season storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4. Pre-season check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5. Submerged outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
 6. Cold weather precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7. Striking underwater object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8. Operation with multiple outboard motors . . . . . . . . . . . . . . . . . . . . . . . . . 88
11. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
12. TOOL KIT AND SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
13. PROPELLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
 9
INDEX

1 GENERAL SAFETY INFORMATION 1

2. SPECIFICATIONS 2

3. PARTS NAME 3

4. LABEL LOCATIONS 4

5. INSTALLATION 5

6. PRE-OPERATING PREPARATIONS 6

7. ENGINE OPERATION 7
8. REMOVING AND CARRYING THE
OUTBOARD MOTOR 8

9. ADJUSTMENT 9

10. INSPECTION AND MAINTENANCE 10

11. TROUBLESHOOTING 11

12. TOOL KIT AND SPARE PARTS 12

13. PROPELLER TABLE 13

14

14
 10
GENERAL SAFETY INFORMATION
ENOM00009-0
SAFE OPERATION OF BOAT
1 As the operator/driver of the boat, you are responsible for the safety of those aboard and
those in other boat around yours, and for following local boating regulations. You should
be thoroughly knowledgeable on how to correctly operate the boat, outboard motor, and
accessories. To learn about the correct operation and maintenance of the outboard motor,
please read through this manual carefully.
It is very difficult for a person standing or floating in the water to take evasive action should
he or she see a power boat heading in his/her direction, even at a slow speed. Therefore,
when your boat is in the immediate vicinity of people in the water, the outboard motor
should be shifted to neutral and shut off.
ENOW00005-0

WARNING
SERIOUS INJURY IS LIKELY IF A PERSON IN THE WATER MAKES CONTACT WITH A MOV-
ING BOAT, GEAR HOUSING, PROPELLER, OR ANY SOLID DEVICE RIGIDLY ATTACHED TO
A BOAT OR GEAR HOUSING.

ENOM0008-A
EMERGENCY STOP SWITCH
The Emergency Stop Switch will stall the outboard motor when the stop switch lanyard is
pulled off. This stop switch lanyard has to be attached to the operator of the outboard
motor to minimize or prevent injuries from the propeller in case the operator falls over-
board.
It is operator’s responsibility to use the Emergency Stop Switch Lanyard.
ENOW00004-A

WARNING
Accidental activation of the Emergency Stop Switch (such as the tether being pulled out in
heavy seas) could cause passengers to lose their balance and even fall overboard, or it
could result in loss of power in heavy seas, strong currents, or high winds. Loss of control
while mooring is another potential hazard.
To minimize accidental activation of the Emergency Stop Switch, the 500 mm (20 inch.) stop
switch lanyard is coiled and can extended to a full 1300 mm (51 inch.).

ENOM00800-A
PERSONAL FLOATATION DEVICE
As the operator/driver and passenger of the boat, you are responsible to wear a PFD (Per-
sonal Flotation Device) while on the boat.
 GENERAL SAFETY INFORMATION 11

ENOM00010-0
SERVICING, REPLACEMENT PARTS & LUBRICANTS
We recommend that only an authorized service shop perform service or maintenance on 1
this outboard motor. Be sure to use genuine parts, genuine lubricants, or recommended
lubricants.

ENOM00011-A
MAINTENANCE
As the owner of this outboard motor, you should be acquainted with correct maintenance
procedures following maintenance section of this manual (See page 68). It is the opera-
tor's responsibility to perform all safety checks and to ensure that all lubrication and main-
tenance instructions are complied with for safe operation. Please comply with all
instructions concerning lubrication and maintenance. You should take the engine to an
authorized dealer or service shop for periodic inspection at the prescribed intervals.
Correct periodic maintenance and proper care of this outboard motor will reduce the
chance of problems and limit overall operating expenses.

Carbon Monoxide Poisoning Hazard

Exhaust gas contains carbon monoxide, a colorless and odorless gas which can be fatal if
inhaled for any length of time.
Never start or operate the engine indoors or in any space which is not well ventilated.

Gasoline
Gasoline and its vapors are very flammable and can be explosive. Use extreme care when
handling gasoline. You should be thoroughly knowledgeable on how to correctly handle
gasoline by reading this manual.
 12
SPECIFICATIONS
ENOM00810-A
MODEL FEATURE
Model M60C M70C M70CX
Type EPTO MFG EPTO MFG

2 Transom heights
S
L z z z z
UL z z z
Tiller handle z z
Remote control z z
Power tilt z z
Gas-assisted tilt z z
Manual tilt

Model M90A2 M115A2 M140A2

Type EPTO EPTO EPTO
S
Transom heights L z z z
UL z z z
Tiller handle
Remote control z z z
Power tilt z z z
Gas-assisted tilt
Manual tilt
(z) These models can be purchased with remote rigging kit or multi function tiller handle.
ENOM00811-B
MODEL NAME EXAMPLE
M140A2 EPTOL
M 140 A 2 E P T O L
Model
Horse Product Miner Starter Steering Tilt Lubrication
descrip- power generation change system system system system Shaft length
tion
T= Power
E= P=Remote trim&tilt
M (X) = Two
Electrical controlࠉ O= S= Short 15 in
stroke 2 and start (Pleasure) G= Oil auto-mxing L= Long 20 in
F= Four stroke - A and up up M= Gas assist Blank= UL=
D= Two stroke
Manual F=Tiller handle Oil Pre-mixing Ultra long 25 in
DI
start (Fisher) Blank=
Manual tilt
 SPECIFICATIONS 13

ENOM01721-0

60C/70C EPTO, 70C/70CX MFG

60C/70C 70C/70CX
Item MODEL
EPTO MFG 2
Overall Length mm (in) Approx. 720 (28.3) Approx. 1280 (50.4)
Overall Width mm (in) Approx. 360(14.2)
L mm (in) 1415 (55.7) 1455 (57.3)
Overall Height
UL mm (in) 1542 (60.7) 1582 (62.3)
L mm (in) 517 (20.4)
Transom Height
UL mm (in) 644 (25.4)
L kg (lb) 115 (254) 105.5 (233)
Weight
UL kg (lb) 117.5 (259) 108 (238)
Output kW (Hp) 60C: 44 (60) / 70C/70CX: 52 (70)
Max. Operating Range min-1 (rpm) 5150-5850
Idle Speed in Neutral Gear min-1 (rpm) 900
Trolling Speed in Forward Gear min-1 (rpm) 750
Engine Type 2-Stroke
Number of Cylinder 3
Bore x Stroke mm (in) 74 x 72.7 (2.91 x 2.86)
Piston Displacement cm3 (Cu in) 938 (57.23)
Exhaust System Through hub exhaust
Cooling System Forced water cooling
Lubrication System Auto-oil mixing Engine oil mixed gasoline

Starting System Electric starter motor Manual

Ignition System Flywheel Magneto C.D. Ignition
Spark Plugs NGK B8HS-10 or BR8HS-10
Alternator 12V, 130W (12V, 11A)
Trim Position 2 5
Fuel Unleaded Regular Gasoline : R+M/2: 87 or higher RON: 91 or higher
Fuel Tank Capacity L (US gal) 25 (6.6)
Engine Oil Genuine motor oil or recommended one (TCW-III)
Fuel : Engine oil Mixing Ratio 120 : 1-50 : 1 50 : 1
Gear Oil mL (fl, oz) Genuine Gear Oil or API GL5, SAE #80 to #90, approx. 900 (30.4)
Gear Reduction Ratio 2.33 (12 : 28)

Remark: Specifications subject to change without notice.

Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
 14 SPECIFICATIONS

ENOM01722-0

90A2, 115A2/140A2 EPTO

Item MODEL 90A2 EPTO 115A2 EPTO 140A2 EPTO

2 Overall Length mm (in) Approx. 690 (27.2) Approx. 747 (29.4)
Overall Width mm (in) Approx. 360 (14.2) Approx. 390 (15.4)
L mm (in) 1435 (56.5) 1560 (61.4)
Overall Height
UL mm (in) 1562 (61.5) 1687 (66.4)
L mm (in) 516 (20.3)
Transom Height
UL mm (in) 643 (25.3)
L kg (lb) 135 (298) 164 (362)
Weight
UL kg (lb) 137.5 (303) 166.5 (367)
Output kW (Hp) 66 (90) 85 (115) 103 (140)
Max. Operating Range min-1 (rpm) 5000-5500 5200-5700
Idle Speed in Neutral Gear min-1 (rpm) 900
Trolling Speed in Forward Gear min-1 (rpm) 750
Engine Type 2-Stroke
Number of Cylinder 3 4
Bore x Stroke mm (in) 86 x 72.7 (3.39 x 2.86) 88 x 72.7 (3.46 x 2.86)
Piston Displacement cm3 (Cu in) 1267 (77.3) 1768 (107.9)
Exhaust System Through hub exhaust
Cooling System Forced water cooling
Lubrication System Auto oil mixing
Starting System Electric starter motor
Ignition System Flywheel Magneto C.D. Ignition
Spark Plugs NGK B8HS-10 or BR8HS-10
Alternator 12V, 130W (12V, 11A) 12V, 330W (12V, 27.5A)
Trim Position 2
Fuel Unleaded Regular Gasoline : R+M/2: 87 or higher RON: 91 or higher
Fuel Tank Capacity L (US gal) 25 (6.6)
Engine Oil Genuine motor oil or recommended one (TCW-III)
Fuel : Engine oil mixing Ratio 120 : 1-50 : 1
Gear Oil mL (fl. oz) Genuine Gear Oil or API GL5, SAE #80 to #90, approx. 900 (30.4
Gear Reduction Ratio 2.00 (13 : 26)

Remark: Specifications subject to change without notice.

Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
 15
PARTS NAME
ENOM01700-0

70 MFG

1 16
3

2 14
15
13 3
3

4
5 17
10
11
12
6

7
9
18
8

19

ENOF02303-0

1 Tilt Handle 10 Clamp Bracket 19 Fuel filter

2 Top Cowl 11 Thrust Rod
3 Hook Lever 12 Anode
4 Water Check Port 13 Throttle Grip
5 Reverse Lock Lever 14 Shift Lever
6 Anti-ventilation Plate 15 Stop Switch
7 Trim Tab 16 Starter Handle
8 Propeller 17 Gas Assistant
9 Water Inlet 18 Spark Plug
 16 PARTS NAME

ENOM01701-0

60/70 EPTO

1 16
3

3 2

3 14
4
12
5
10
11
6 13

7 15
9

17
20
18

19

21
ENOF02304-0

1 Tilt Handle 10 Clamp Bracket 19 Oil Filter

2 Top Cowl 11 Thrust Rod 20 Spark Plug
3 Hook Lever 12 Power Trim & Tilt 21 Tilt Stopper
4 Water Check Port 13 Anode
5 PTT Switch 14 Fuel Connector
6 Anti-ventilation Plate 15 Battery Cords
7 Trim Tab 16 Filler Lid
8 Propeller 17 Oil Tank
9 Water Inlet 18 Fuel Filter
 PARTS NAME 17

ENOM01702-0

90, 115/140 EPTO

1 13

2 2 3
3

4
12
9 11
10

6
8

14
17
15

16
18
ENOF02305-0

1 Top Cowl 10 Manual Valve (Port side) 18 Tilt Stopper

2 Hook Lever 11 Power Trim & Tilt
3 Water Check Port 12 Battery Cords
4 Gear Case 13 Filler Lid
5 Anti-ventilation Plate 14 Oil Tank
6 Trim Tab 15 Fuel Filter
7 Propeller 16 Oil Filter
8 Water Inlet 17 Spark Plug
9 Clamp Bracket
 18 PARTS NAME

ENOM00822-0

Remote control box & Fuel tank

10
3 1 9

3
2 11

7
6
8
13
14
12

ENOF00127-F2

1 Control Lever 9 Fuel Gauge

2 Neutral Lock Arm 10 Air Vent Screw
3 PTT Switch 11 Fuel Tank Cap
4 Free Throttle Lever 12 Fuel Connector (Engine Side)
5 Main Switch 13 Primer Bulb
6 Stop Switch 14 Fuel Connector (Fuel Tank Side)
7 Stop Switch Lock
8 Stop Switch Lanyard
 19
LABEL LOCATIONS
ENOM00019-A

Warning label locations

4 1
2
4

6
8

ENOF02374-2
 20 LABEL LOCATIONS

1. Warning label urge to read the owner’s 6. Warning regarding gasoline. (See
manual. page 34)

ENOF00005-E

4 3C7-72180-3

2. Warning regarding rotating object.

7. Warning
page 34).
regarding gasoline (See

ENOF00005-L

3C7-72182-2
8. Warning regarding gasoline (See
3. Warning regarding high voltage. page 34).

3C8-72181-0

4. Warning regarding engine oil replenish-

ment.

ENOF00005-M
9. Warning regarding gasoline (See
page 34).

3T1-72043-0
For RC model
5. Warning label regarding stop switch
lanyard. ENOF00005-F

ENOF00005-D
 LABEL LOCATIONS 21

ENOM01001-A

Serial number label locations

1)
2)
3)
4
4)
5)
6)

ENOF02306-1

1. Model code (Model name)

2. Rated power
3. Dry mass weight
4. Serial No.
5. Manufacturer name
6. Manufacturer address
 22
INSTALLATION
ENOM00024-A Do not operate the outboard motor until it
1. Mounting the outboard motor on has been securely mounted on the boat in
accordance with the instructions below.
boat
ENOW00009-0
ENOW00006-B

WARNING WARNING
z Mounting the outboard motor without
Before installing the outboard motor on the following this manual can lead to unsafe
boat, hang the outboard motor with the conditions such as poor maneuverabil-
hoist or equivalent device by attaching the ity, lack of control or fire.
engine hanger to the outboard. Use the z Loose clamp screws and/or mounting
hoist with allowable load is 250 kg (550 lbs) bolts can lead to the release or displace-
or above. ment of the outboard motor, possibly
resulting in lost of control and/or serious
5 personal injury. Be sure that fasteners
are tightened to the specified torque (30
Nm (3.0 kgf) 13 ft-lb). Check the fasten-
ers for tightness from time to time.
z Be sure to use outboard mounting fas-
teners included in the outboard motor
package or their equivalents in terms of
size, material, quality and strength.
Tighten fasteners to the specified torque
(30 Nm (3.0 kgf) 13 ft-lb). Test cruise to
check if fasteners are tightened
securely.
z Outboard motor mounting must be per-
formed by trained service person(s)
using lift or hoist with sufficient capac-
ity.

Outboard motor mounting must be per-

formed by trained service person(s) using
ENOF02387-0
lift or hoist with sufficient capacity.
ENOW00006-0

WARNING
Most boats are rated and certified in terms
of their maximum allowable horsepower,
as shown on the boat’s certification plate.
Do not equip your boat with an outboard
motor that exceeds this limit. If in doubt,
contact your dealer.
 INSTALLATION 23

ENOM00025-A
Position ... Above keel line
„ Single-engine Installation
Set engine at center of boat.
1
1 10−30 mm
(0.4−1.2 in)
2
ENOF01706-B

1. Bottom of hull
2. Anti ventilation plate
ENOW00007-0
2
CAUTION
z Before beginning the running test, check 5
ENOF011410 that the boat with maximum capacity
1. Center of boat loading floats on the water in a proper
2. Boat transom attitude. Check the position of water
surface on the driveshaft housing. If the
ENOM01201-0 water surface is near the bottom cowl-
ing, in high waves, water may enter the
„ Twin-engine Installation engine cylinders.
When installing two outboard engines, be z Incorrect outboard motor mounting
sure to keep an interval of approximately height or existence of underwater
580 mm (22.8 in) between the two. object(s), such as hull bottom design,
bottom surface conditions or underwa-
ter accessories, can cause water spray
1
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.

ENOF01823-0 ENOM00830-A

1. Approx 580 mm (22.8 in)

Mounting bolts
Power trim and tilt type
ENOM00026-0
1. To attach the outboard motor to the
Transom matching
boat, use the bolts to secure the out-
Be sure that the anti ventilation plate of the
board motor brackets on transom
outboard motor is 10–30 mm (0.4–1.2 in)
board.
below the bottom of hull.
If the above condition cannot be met due
to the shape of the bottom of your boat,
please consult your authorized dealer.
 24 INSTALLATION

z Tighten the bolts sufficiency, otherwise

falling down of outboard could be hap-
pened.

ENON00003-0

2 4 Notes
1. Apply sealing agent, such as silicone
sealed between the bolts and the tran-
som board holes before tightening the
bolts.
3 2. Be sure to tighten the mounting bolt
1 nuts to the specified torque.
(30 Nm (3.0 kgf) 13 ft-lb)
ENOF02317-0

1. Bolt (12 mm × length 105 mm) ENOM00840-A

5
2. Washer (small diameter)
3. Washer (large diameter) 2. Remote control device
4. Nut installation
327 (12.9')
1 ENOW00944-A

WARNING
51 (2') When using other than Tohatsu’s genuine
17.5 (0.7') remote control box, DO NOT select the one
17.5 (0.7')
17.5 (0.7')
without neutral safety switch that prevents
13ø 254 in-gear start.
(10') Use of remote control box without neutral
safety switch can allow start of engine with
gear at other than neutral shift, potentially
leading passengers to falling or causing
56 passenger to be thrown overboard.
(2.2)

It is recommended that you consult w i t h

251 (9.9')
ENOF02318-0
your authorized dealer for installation
adjustment of the remote control device.
1. Top of transom

ENOW00008-A

CAUTION
z Mounting bolts should be installed with
the bolt head at inside surface of the
transom. Mounting bolts installed with
the threaded end at the inside surface of
the transom can cause personal injury.
 INSTALLATION 25

ENOM00850-0
Prepare a cable that is 300-450mm (11.8-
Remote control box location
17.7in) longer than the measured distance.
Temporarily pull the cable along the
intended cable route to check its length is
sufficient.
3 Connect the remote control cable to the
engine, then run the cable to the remote
1, 2 control box, making sure it is not sharply
bent, too taut and free from obstructions
that could interfere with steering.
ENOM01703-0
ENOF008411 „ Installation of the Remote Control
1. Shift cable Cable (engine side) and the Cord
2. Throttle cable
3. Cord assembly B
Assembly (Wiring Harness) : 5
ENOW00100-A
Install the remote control box in a position
where it is easy to reach and operate the CAUTION
controls. Be careful not to loop the remote control
Make sure there are no obstacles that can cables to a diameter of 406 mm (16 inches)
interfere with the operation of the remote or less. Otherwise, it affects the service life
control cable. of the cable.

ENOM00850-0 ENOM01704-0
Remote control cable length 60/70
ENOW00100-A 1. Detach the bracket and set cord
CAUTION assembly B and the remote control
cables in position.
Be careful not to loop the remote control
After fixing the remote control cables to
cables to a diameter of 406 mm (16 inches)
or less. Otherwise, it affects the service life the bracket, re-secure the bracket to
of the cable. the lower cowl.

3
ENOF00842-0
2
ENOF02308-0

Measure the distance from the remote 1. Cord grommet

control box to the outboard motor where 2. Cord assembly B
3. Battery cord
the remote control cable should be routed.
 26 INSTALLATION

3. Move the remote control lever to the

1 “FORWARD” “NEUTRAL” and
4 “REVERSE” positions to confirm that
5 the shift is working properly, then set
3 the lever to “NEUTRAL”.

2 3
7
6 1
3
2 ENOF02309-0

1. Remote control grommet 4

2. Battery cord grommet
3. Clutch cable ENOF02311-0

5 4.
5.
Extension cord
Throttle cable 1.
2.
Remote control cable
Lock nut
6. Cord assembly B
7. Battery cord 3. Cable joint
4. Approx. 10 mm (0.39 in)

2. Detach the throttle and shit cable joints

4. Double-check that the remote control
by removing the R-pins.
cables (i.e., the throttle cable and shift
cable) have been connected correctly.
Move the remote control lever forward
to the first point at which it engages
2 (approx. 32°). The cable which moves
first when the lever is turned should be
the shift cable. Check that the shift
lever is in “NEUTRAL” position and that
3 the free throttle lever is fully closed
1 when the remote control cables have
been connected.
ENOF02310-0

1. R-pin
2. Throttle cable joint 4
3. Shift cable joint
2
Screw the tip of the remote control 1
cable into the cable joint up to approx.
10 mm (0.39 inch), then lock them with 3
a lock nut. Here, apply grease to the
hole of the cable joint.
ENOF023121

1. Free throttle lever

2. Fully opened
3. Fully closed
4. Approx. 32°
 INSTALLATION 27

* The advancer arm on the engine should

be contact with the stopper of the cylin-
der crank case assembly so that the
throttle valve of the carburetor is to be
fully closed condition.
1
2
2 ENOF02315-0

1. Cord assembly A
2. Cord assembly B
1
ENOW01705-0
90
3 ENOF02313-0 1. Detach the upper engine cover. 5
1. Advancer arm
2. Stopper (Throttle fully closed side)
3. Stopper (Throttle fully opened side)

5. Adjust the cable joints until the hole of

each is aligned with the advancer arm
pin.
After adjustment, lock each cable joint
with the nut and secure it with the R-
pin.

2 1 ENOF02316-0

3 1. Upper grommet
2. Cord assembly B hole
1
2. Detach the upper grommet cord clamp
bolt.
4

2 ENOF02314-0

1. Cable joint
2. Nut
3. Washer
4. R-pin

6. Connect cord assembly B to cord 1 ENOF02320-0

assembly A 1. Cord clamp

Connect the pink and light-blue leads 3. Detach the throttle and shit cable joints
from cord assembly A and B together. by removing the R-pins.
 28 INSTALLATION

4. Move the remote control lever to the

“FORWARD” “NEUTRAL” and
“REVERSE” positions to confirm that
the shift is working properly, then set
the lever to “NEUTRAL”.

1 ENOF02319-0
3
1. Cable joint
4. Move the remote control lever to the

5
“FORWARD” “NEUTRAL” and
“REVERSE” positions to confirm that
ENOF02322-0
the shift is working properly, then set
1. Bolt
the lever to “NEUTRAL”. 2. Cord clamp
3. Upper grommet

ENOW01706-0 2
115/140
1. Detach the upper engine cover.
3
5 4
1 5
4 ENOF02323-0

1. Shift arm
2. Throttle cable joint
3. Shift cable joint
4. R-pin
5. Washer

1 5. Double-check that the remote control

3 2 ENOF02321-0 cables (i.e., the throttle cable and shift
1. Upper grommet cable) have been connected correctly.
2. For throttle cable Move the remote control lever forward
3. For shift cable
4. For cord assembly B to the first point at which it engages
5. For engine cable harness (approx. 32). The cable which moves
first when the lever is turned should be
2. Detach the upper grommet cord clamp the shift cable. Check that the shift
bolt. lever is in “NEUTRAL” position and that
3. Detach the throttle and shit cable joints the free throttle lever is fully closed
by removing the R-pins. when the remote control cables have
been connected.
 INSTALLATION 29

8. Using the washers and R-pins to

4 adjust the thread length, connect the
throttle and shift cables to the pins on
2 the engine-side.
1
9. Insert the outer groove of each cable
into the cable grip provided in the
3 lower engine cover. (115, 140)
Attach the cord clamps and fix the
cables securely with the bolts.
ENOF023121

1. Free throttle lever

2. Fully opened ENOM01707-0

3. Fully closed
4. Approx. 32° 3. Drag link installation

* The advancer arm on the engine should (Standard accessories for EPTO types)
5
be contact with the stopper of the car- Incorrect or unstable installation of the
buretor throttle valve to enable it to be Drag Link assembly can result in accidents
fully closed. while riding the boat or breakage of the
hull.
Installation of the Drag Link Assembly by
2
your dealer is highly recommended.
ENON00932-0
Note
Depending on the steering cable manufac-
ture, spacers (optional) may be required.

1. Connect the Drag Link rod to the tip of

1 the steering cable. Tighten the rod
using the nylon nut, making sure the
rod can swing freely.
ENOF02324-0 2. Connect the other tip of the rod to the
1. Advancer arm steering bracket with a bolt, first apply-
2. Carburetor throttle valve (fully closed side) ing a collar and washer. The bolt head
must face downward.
6. Connect cord assembly B to cord
ENON00933-0
assembly A, and connect the meter Note
cord assembly.
Apply grease in required places.
7. Connect the pink and light-blue leads
from cord assembly A and B to each
other.
 30 INSTALLATION

In case battery electrolyte comes in con-

12 tact with:
z Skin, flush thoroughly with water.
z Eye, flush thoroughly with water, and
11 then seek immediate medical treatment.
8 In case battery electrolyte is swallowed:
z Seek immediate medical treatment.
7 9
4 10 ENOW00013-A

6 WARNING
4 2 Battery generates explosive hydrogen gas.
5 4 Be sure to:
1 3 z Charge the battery in a well-ventilated
ENOF02325-0 place.
5 1. Drag link rod z Place the battery away from any source
2. Grease of fire, sparks and open flames such as
3. Nylon nut burners or welding equipment.
4. Washer
z Do not smoke near the battery when the
5. Bolt
6. Collar battery is charging.
7. Nut z Do not charge the battery when the
8. Spacer (option) electrolyte level is low. Otherwise, the
9. Tip of cable
battery will be damaged and may cause
10. Seal ling
11. Steering bracket malfunction.
12. Apply grease inside the bracket bolt
ENOW00014-0

ENOM00029-A
CAUTION
4. Battery installation
z Make sure that the battery leads do not
get stuck between the outboard motor
ENOW00012-0
and boat when turning, etc.
WARNING z The starter motor may fail to operate if
the leads are incorrectly connected.
Battery electrolyte contains sulfuric acid z Be sure to correctly connect the (+) and
and thus is hazardous, causing a burn if it (—) leads. If not, the charging system
comes in contact with your skin, or poison- will be damaged.
ous if swallowed. z Do not disconnect the battery leads
Keep battery and electrolyte away from from battery while the engine is operat-
reach of children ing, the electrical parts could be dam-
When handling the battery, be sure to: aged.
z Read all warnings shown on the battery z Always use a fully charged battery.
case
z Prevent electrolyte from coming in con- ENOW00015-0

tact with any part of your body. Contact

can cause serious burn or, if it comes in CAUTION
contact with your eye, loss of sight. Use Do not use a battery that is not recom-
safety glasses and rubber gloves. mended. Use of a battery not recom-
 INSTALLATION 31

mended can lead to poor performance of, ENOM01708-0

and/or damage to, the electrical system.

5. Tiller handle installation
ENON00006-B
Note ENOW01706-0
MFG types
Recommended battery: 12V 70AH/5HR, 1. Connect the throttle cable coming from
800 (Cold Cranking Amps (CCA), In case of
the motor to the handle, then fix it with
cold whether: 12V100AH/5HR (850CCA))
Specifications and features of batteries vary a nylon nut. After that, place the plate
among the manufacturers. Consult the in the outer groove, and fix it with
manufacturer for details. screws.
* The battery should be purchased sepa-
rately and is not supplied with the outboard
motor.
1
1. Place the battery box in a convenient
position away from possible water
5
2 2
spray. Securely fasten both the box
3
and the battery so they do not shake
loose. 4
2. Connect the positive lead (+) to the
positive terminal (+) of the battery, and
then connect the negative lead (—).
When disconnecting the battery
always remove the negative lead (—) 5 ENOF02326-0

1. Throttle cable
first. After connecting the positive ter- 2. Screw
minal (+), securely place a cap on it to 3. Plate
4. Handle
prevent short circuits. 5. Nylon nut
2. Install the steering handle to the motor
with two bolts.

2
6
3
1
2
1 ENOF00022-0

1. Battery cord (red) 5

2. Battery cord (black)
4 ENOF02327-0
3
1. Handle
2. Handle B
3. Bolt
4. Plate
5. Friction bolt
6. Bushing
 32 INSTALLATION

ENOM00045-A could lead to the propeller coming off

during operation.
6. Propeller installation

ENOW00085-A
Propeller must be selected that will allow
WARNING the engine to reach recommended min-1
(rpm) when cruising at wide-open throttle.
Do not begin propeller removal and instal-
lation procedure with spark plug caps Wide-open throttle min-1 (rpm) range
attached, shift in forward or reverse, main 60/70 : 5150 – 5850 min-1 (rpm)
switch at other than “OFF”, engine stop
90 : 5000 – 5500 min-1 (rpm)
switch lock attached to the switch, and
115/140 : 5200 – 5700 min-1 (rpm)
starter key attached, or engine could acci-
dentally start leading to serious personal Genuine propellers are listed on PROPEL-
injury. LER TABLE of this manual (See page 92).
5 Disconnect battery cable if possible.

ENOW00085-0
1. Remove the split pin, propeller nut and
washer.
WARNING 2. Remove the propeller and thrust
Do not hold propeller with hand(s) when holder.
loosening or tightening propeller nut. Put a 3. Apply water proof grease to the pro-
piece of wood block between propeller
peller shaft before installing a new pro-
blade and anti-ventilation plate to hold pro-
peller. peller.
4. Install the thrust holder, propeller,
stopper, washer and propeller nut onto
the shaft.

4 7
6
5

ENOF00084-B 3 1
2
ENOW00086-0

CAUTION ENOF01336-A

z Do not install propeller without thrust 1. Propeller

2. Thrust holder
holder, or propeller boss could be dam- 3. Bush
aged. 4. Stopper
z Do not reuse split pin. 5. Washer
z After installing split pin, spread the pin 6. Propeller nut
7. Split pin
apart to prevent it from falling out which
 INSTALLATION 33

5. Tighten the propeller nut to specified

torque with holding the propeller by
wood block. And align one of grooves
to propeller shaft hole.
Propeller nut torque:
35 Nm (25 ft-lb, 3.5kgf-m)

5
ENOF00084-B

6. Install a new split pin into the nut hole

and bend it.
 34
PRE-OPERATING PREPARATIONS
ENOM00030-A
these adverse effects are caused because
1. Fuel handling the ethanol in the gasoline can absorb
moisture from the air, resulting in a separa-
ENOW000017-0
tion of the water/ethanol from the gasoline
CAUTION in the fuel tank.
These may cause increased:
Use of improper gasoline can damage your
z Corrosion of metal parts
engine. Engine damage resulting from the
use of improper gasoline is considered z Deterioration of rubber or plastic parts
misuse of the engine, and damage caused z Fuel permeation through rubber fuel
thereby will not be covered under the lim- lines
ited warranty. z Starting and operating difficulties

ENOM00031-A If the use of gasoline containing alcohol is

FUEL RATING inevitable, or presence of alcohol is sus-
TOHATSU engines will operate satisfacto- pected in the gasoline, it is recommended
rily when using a major brand of unleaded
6
to add a filter that has water separating
gasoline meeting the following specifica- capability, and check the fuel system for
tions: leaks and mechanical parts for corrosion
USA and Canada — having a posted and abnormal wear more frequently.
pump Octane Rating of 87 (R+M)/2 mini- And, in case any of such abnormality is
mum. Premium gasoline (92 [R+M]/2 found, discontinue the use of such gaso-
Octane) is also acceptable. Do not use line and contact our dealer immediately.
leaded gasoline. If the outboard motor will only be used
Outside USA and Canada — Use infrequently, please see the remarks on
unleaded gasoline with declared octane fuel deterioration in the STORAGE chapter
rating of 91 RON or over. Use of premium (P 84) for additional information.
gasoline of 98 RON is also allowed. ENOW00020-0

ENOM00032-A CAUTION
GASOLINES CONTAINING
When operating a TOHATSU engine on
ALCOHOL gasoline containing alcohol, storage of
The fuel system components on your gasoline in the fuel tank for long periods
TOHATSU engine will withstand up to 10% should be avoided. Long periods of stor-
ethyl alcohol (hereinafter referred to as the age, common to boats, create unique prob-
"ethanol"), content in the gasoline. But if lems. In cars, alcohol blend fuels normally
are consumed before they can absorb
the gasoline in your area contains ethanol,
enough moisture to cause trouble, but
you should be aware of certain adverse boats often sit idle long enough for phase
effects that can occur. Increasing the per- separation to take place. In addition, inter-
centage of ethanol in the fuel can also nal corrosion may take place during stor-
worsen these adverse effects. Some of
 PRE-OPERATING PREPARATIONS 35

age if alcohol has washed protective oil ENOW0002A-A

films from internal components.

CAUTION
ENOW00018-0
Use of engine oils that do not meet these
requirements will result in reduced engine
WARNING life, and other engine problems.
Fuel leakage can cause fire or explosion,
potentially leading to severe injury or loss ENOW00603-0

of life. Every fuel system part should be

checked periodically, and especially after CAUTION
long term storage, for fuel leak, change of Do not mix different brands of oil. Mixing
hardness of rubber, expansion and/or cor- different brands of oil, or different types of
rosion of metals. In case any indication of oil even if the brand is the same, may cause
fuel leakage or degradation of fuel part is gelling, resulting in possible filter screen
found, replace relevant part immediately blockage. This could result in serious
before continuing operation. engine damage because of impaired lubri-
cation performance.
ENOM01660-0

2. Engine oil recommendation Use a genuine engine oil or recommended 6

one (TCW3). Refer to your Distributor.
ENOW00022-A Will not recommended use of other two
CAUTION stroke engine oil.

The engine oil is drained for shipping from Pre-mixing type

the factory. Be sure to fill the engine to the Add engine oil into fuel oil tank. The mixing
proper level before starting engine. (To ratio with gasoline is 50 : 1 (50 parts gaso-
properly fill the engine with oil follow the line and one part oil). Mix well by hand. The
instructions, See page 70) mixing ratio during break-in running is 25 :
1 1.
2
Mixing Ratio
Gasoline : Engine Oil
During break-in 25 : 1
After break-in 50 : 1

Fuel by Oil Mixing (25:1, 50:1)

3 Oil
1.0L
(25:1)
25 : 1

0.5L
0.4L (10 : 0.4) (25:0.5)
ENOF01963-0 50 : 1
0.2L
(10 : 0.2)
1. Genuine of recommended engine oil 0 2L 10L 25L 30L
2. Filler lid
3. Oil tank cap Gasoline ENOF01708-0
 36 PRE-OPERATING PREPARATIONS

ENOM01003-0
Engine oil – gasoline mixing
procedure
ENOW00937-0

CAUTION
z Do not use other than two stroke engine
oil with specified grade, or the engine
may be damaged.
z Do not use fuel prepared in other than
specified mixing ratio.
- Lack of engine oil can cause severe
engine trouble such as piston seizure.
- Excess of engine oil can shorten spark
plug life, and/or cause increase of nox-
ious exhaust.

For quantities of engine oil and gasoline to

6 be pre-mixed, refer to table in previous
page.
„ When portable fuel tank is used for ENOF01709-0
operation of outboard motor(s):
2 Pour engine oil into fuel container, and
1 Pour engine oil into fuel tank, and then, then, gasoline.
gasoline.
3 Put cap on the container, and close
2 Put cap on the tank, and close tightly. tightly.
3 Close air vent plug tightly. 4 Shake the container to mix engine oil
ENOW00938-0
and gasoline well and even.
WARNING 5 Pour the mixture into fuel tank.
ENON00922-0-0
Loose cap or air vent plug can cause leak Notes
of fuel during shaking the tank.
z It is recommended to pre-mix by using
4 Shake the tank to mix engine oil and separate fuel container. Attempting to
gasoline well and even. pre-mix in the fuel tank built-in the boat
can make the mixture uneven.
„ When fuel tank built in the boat is z If built-in fuel tank is used for mixing,
pour engine oil into the tank little by little
used for operation of outboard
while putting gasoline into the tank.
motor(s):
1 Prepare separate fuel container for pre-
mixing.
 PRE-OPERATING PREPARATIONS 37

ENOM01003-0
Loosen the air vent screw on the oil pump
Auto mixing type
ENOW00604-0
to purge the air, and tighten it when all air,
as seen through the vinyl pipe on the oil
CAUTION pump side, has been purged.
z In the unlikely event that gasoline by
mistake is filled into the oil tank, drain 60/70
the oil tank completely, and consult an
authorized service shop for advice. 1
z Check the amount of oil in the oil tank
visually before starting the engine. Run-
ning out of oil at sea is a cause for
potential disaster.

The required amount of engine oil is auto-

matically supplied from the oil tank, 4
through the oil pump, according to the
engine running conditions. Gasoline is fed
over a separate feeding line.
4 2 6
„ During break-in 3 ENOF02330-0

Add engine oil into fuel tank. The mixing 1. Air vent screw
2. To check valve
ratio with gasoline during break-in is 50:1 3. From oil filter
(50 parts oil and one part gasoline). Mix 4. Vinyl pipe
well by hand.
90, 115/140
Gasoline : Engine Oil
During break-in 50 : 1 1
2
ENOM00644-1
Replenishing oil in the engine oil tank.
1. Open the filler lid from the top cowl.
2. Open the oil tank cap. 4
3. Fill the oil tank with the genuine engine 3
oil.
4. After replenishment of the oil tank, be
sure to close the oil tank cap tightly. 4
ENOF02331-0

ENOM00645-0 1. Air vent screw

Oil pump air vent 2. To check valve
3. From oil filter
Visually check whether there is air in the oil 4. Vinyl pipe
through the vinyl pipe connecting the oil
tank with the oil pump. If present, Purge
the air as follows:
 38 PRE-OPERATING PREPARATIONS

ENON00608-0 z Dismount fuel tank from the boat.

Note z Place the fuel tank away from every
Wipe off any spilled oil with a rag, and dis- source of ignition, such as sparks or
pose of it. open flames.
z Do the work outdoors or in a well venti-
ENOM00043-B lated area.
z Wipe off gasoline well immediately if
3. Fuel filling spilled.
z
ENOW00019-0 After cleaning gasoline tank:
z Wipe off gasoline well immediately if
WARNING spilled.
Do not fill the fuel tank over capacity. The z If the fuel tank is disassembled for
rise of gasoline temperature may cause cleaning, reassemble carefully. Imper-
gasoline to expand which, if overfilled, may fect assembly may cause a fuel leak,
leak through air vent screw when it is open. possibly leading to fire or explosion.
Leaking gasoline is a dangerous fire haz- z Dispose aged or contaminated gasoline
ard. in accordance with local regulations.

6 ENOW00028-A ENOW00029-A

WARNING WARNING
Consult an authorized dealer for details on When opening fuel tank cap, be sure to fol-
handling gasoline, if necessary. low the procedure described below. Fuel
could blast out through the fuel tank cap in
Gasoline and its vapors are very flammable case the cap is loosened by using another
and can be explosive. procedure when internal pressure of fuel
tank is raised by heat from sources such as
When carrying a fuel tank containing gaso- sun light.
line:
z Close the fuel tank cap and air vent 1. Full open the air vent screw on the fuel
screw of fuel tank cap, or gasoline vapor tank cap and release internal pressure.
will be emitted through the air vent
screw, creating a fire hazard.
z Do not smoke. 1

When or before refueling: 2

z Be sure to remove the static electricity
charged in your body before refueling.
z The sparks due to static electricity may
cause explosion of flammable gasoline.
z Stop the engine, and do not start the
engine during refueling.
ENOF00027-B
z Do not smoke.
z Be careful not to overfill fuel tank. Wipe
1. Air vent screw
up any spilled gasoline immediately. 2. Fuel tank cap

When or before cleaning the gasoline tank: 2. Open the fuel tank cap slowly.
 PRE-OPERATING PREPARATIONS 39

3. Fill the fuel carefully not to over flow.

SAFE FILL
LEVEL
25 L
NIVEAU
MAXIMUM
ENOF00030-A

4. After filling the tank, close the fuel tank

cap.

6
 40 PRE-OPERATING PREPARATIONS

ENOM00033-A

4. Break-In

Your new outboard motor and lower unit ENOW00023-0

require break-in for the moving compo- CAUTION

nents according to the conditions
Operating the outboard motor without
described in the following time table.
break-in can shorten service life of the
Please refer to ENGINE OPERATION sec- product.
tion (See page 44) to learn how to cor- If any abnormality is experienced during
rectly start and operate the outboard the break-in:
motor. z Discontinue the operation immediately.
z Have the dealer check the product and
ENOW00024-A
take proper action(s) if necessary.
WARNING
ENOM01004-A
Do not operate the outboard motor in
Fuel mixing ratio for break-in
6
closed area or area with no forced ventila-
tion. „ Pre-mixing type
Exhaust gas emitted by this outboard
Gasoline 25: Genuine Engine Oil 1
motor contains carbon monoxide that will
cause death if inhaled continuously. Inhal- „ Auto-mixing type
ing the gas initially causes symptoms such
Gasoline 50: Genuine Engine oil 1
as feeling of sickness, drowsiness and
headache. ENON00935-0

During operation of the outboard motor: Note

z Keep peripheral area well ventilated. When using genuine engine oil or the rec-
z Always attempt to stay on the windward ommended one (TCW3).
side of emission.
ENON00008-0
Note
Proper break-in allows outboard motor to
deliver it full performance for longer service
life.

1–10 min 10 min – 2 hrs 2–3 hrs 3–10 hrs After 10 hrs
Less than 1/2 Less than 3/4 Full throttle
Throttle Position Idle 3/4 throttle
throttle throttle available
Approx. 4000
Full throttle run min-1 (rpm). Full
Approx. 3000
Speed allowed for 1 throttle run
min-1 (rpm) max
min every 10 min allowed for 2
min every 10 min
 PRE-OPERATING PREPARATIONS 41

ENOM00039-0
115/140
5. Warning system

If outboard motor encounters an abnormal 2

condition of fault, the warning buzzer will
emit a continuous beep or intermittent
short beeps and the warning lamp (LED)
will synchronize with the buzzer and
engine speed will be limited (engine will not
1
be stopped).

See next page for conditions which will ENOF02389-0

lead to an abnormal condition or fault. 1. Warning lamp (Oil)

2. Warning lamp (Over heat)

ENOM00040-C
Location of warning buzzer and
lamp 6
„ Warning buzzer
RC model: Located inside the remote con-
trol.
Tiller handle model (Oil auto mixing type
only): Located inside of the top cowl.
„ Warning lamp (LED)
RC model: Located in the tachometer.
Tiller handle model : none
60/70, 90

ENOF00851-A

1. Warning lamp
 42 PRE-OPERATING PREPARATIONS

ENOM01711-0
Warning indicators, faults and remedy
60/70, 90
Warning indicators

Description of faults Remedy

Sound
Low
Lamp speed High speed ESG
ESG

ON Engine speed exceeds

Off - - 5900 min-1 (rpm) (90) 1
6150 min-1 (rpm) (60/70) maximum allowable min-1 (rpm)

Continuous *1 ON *1 - - Low oil level *1 2

ON
Continuous *1 - 3500 - Over heating 3
min-1
(rpm)

ON
Continuous *2 - 3500 - Low cooling water pressure 3
min-1
(rpm)

*1 Except for MF type

6 *2 Equip this function with 90 model

115/140
Warning indicators
Low Description of faults Remedy
Sound Lamp speed High speed ESG
ESG

ON Engine speed exceeds

Off - - 1
6000 min-1 (rpm) maximum allowable min-1 (rpm)

ON
Continuous ON 2800 - Remaining oil, less than 1.5 L 2
min-1
(rpm)

Off ON - - Remaining oil, less than 3 L 2

Continuous ON - - Over heating 3

ON
Continuous *1 - 2800 - Low cooling water pressure 3
min-1
(rpm)

ON
Off - 1500 - Incorrect connection of cord 4
min-1
(rpm)

*1 Activate at over 2800 min-1 (rpm)

High speed ESG (Electronic Safety Governor)

High speed ESG is a device to prevent over revolution of the engine. If the load to the engine becomes light for some
reason, it runs at a higher speed than the usual. In such the case, the buzzer sounds and the ESG is activated not to
ignite the spark plug, therefore, the engine speed varies and be controlled under 6000min-1 (rpm).
 PRE-OPERATING PREPARATIONS 43

Low speed ESG

Low speed ESG is a device to prevent the engine from getting damage. If the engine has problems regarding
cooling water, oil pressure, and sensors, the low speed ESG is activated not to ignite the spark plug, and disable
fueling therefore, the engine speed varies and be controlled under 3000min-1 (rpm).

Remedy
1. Reduce the throttle to less than half
opening, and move to safe place
quickly, and stop the engine.
Check the propeller for bent or dam-
aged blades.
Consult an authorized dealer if engine
shows the same result even after
replacing propeller with new one.
2. Move to safe place quickly, and set the
Remote Control Lever to Neutral
(buzzer will stop). And then, stop the 6
engine.
Check the engine oil level, and add
engine oil if necessary.
Start the engine, and move the
Remote Control Lever Forward care-
fully. Confirm that the indicator lamp
goes out.
3. Move to safe place quickly, and check
the discharge of cooling water from the
water check port at idle speed and
stop engine.
Remove any foreign matter on the gear
case and propeller if necessary. Con-
sult an authorized dealer if no dis-
charge of cooling water.
4. Consult an authorized dealer.
 44
ENGINE OPERATION
ENOM00042-0 ENOW00027-C

Before starting CAUTION

ENOW00022-C Before starting engine for the first time
after reassembling engine or off-season
CAUTION storage, disconnect stop switch lock and
crank approximately 10 times in order to
The engine oil is drained for shipping from
circulate the engine oil.
the factory. Be sure to fill the engine oil to
the proper level before starting engine. ENOM00656-A
(Follow the instruction. See page 35)
1. Engine oil feeding
1
2
When the engine is new or have been left
without operation for a long time, or just
after the engine is overhauled, be sure to
execute the following operation for forc-
edly feeding the engine oil to the oil line
before starting the engine.
3
a. Disconnect the link rod by turning the
7 rod snap (1) interlocking with the oil
pump as shown in the figure.
ENOF01963-0
b. Make sure that the oil pump control
1. Genuine of recommended engine oil
2. Filler lid
lever (2) is set at open side position (3).
3. Oil tank cap c. Idle the engine for more than 30 min-
utes.
ENOW00022-B
d. Reset the link rod (4) to the advancer
CAUTION arm (5).
Be sure to mix the engine oil with gasoline
(Follow the instruction. See page 35) 60/70

ENOF01710-0 4
1 ENOF02332-0
 ENGINE OPERATION 45

ENOM00044-C

2. Fuel feeding
ENOW00029-A
3
WARNING
When opening fuel tank cap, be sure to fol-
low the procedure described below. Fuel
could blast out through the fuel tank cap in
case the cap is loosened by using another
procedure when internal pressure of fuel
2 tank is raised by heat from sources such as
ENOF02333-0
sun light.
1. Rod snap
2. Control lever
3. Open side position 1. Full open the air vent screw on the fuel
4. link rod tank cap.
90/115/140
1
1
2
7
4

ENOF00027-B

1. Air vent screw

5 2. Fuel tank cap
ENOF02335-0

2. Connect the fuel connector to the

engine and fuel tank.

2 3
2
3 ENOF02334-0

1. Rod snap
2. Control lever
3. Open side position ENOF02388-0
4. link rod
5. Advancer arm 1. Fuel connector
2. Pull
3. Insert
 46 ENGINE OPERATION

And be sure to remove the propeller, when

2 starting the engine in the test tank. (See
1 page 78)
Run the engine only at idling.

1
ENOF00861-A

1. Pull
2. Insert
3. Squeeze primer bulb until it becomes 2
stiff to feed fuel to carburetor. Direct ENOF00863-0
arrow mark upward when priming. 1. Test tank
2. Water
1 3. Over 10 cm (4 in.)

ENOW00036-0

7 CAUTION
Be sure to stop engine immediately if cool-
2 ing water check port is not discharging
ENOF00862-0
water, and check if cooling water intake is
1. Engine side
2. Fuel tank side blocked. Operating engine could lead to
overheating potentially leading to engine
Do not squeeze primer bulb with engine damage. Consult an authorized dealer if
the cause cannot be found.
running or when the outboard motor is
tilted up. Otherwise, fuel could overflow. ENOW00032-A

ENOM00045-A
CAUTION
3. Starting the engine
Do not keep turning starter motor for over
ENOW00036-A
5 seconds, or the battery may be con-
sumed, potentially making the engine start-
CAUTION ing impossible and/or damaging the
starter.
When the engine is started in the test tank, If cranking over 5 seconds fails to start
to avoid over heating and water pump engine, return main switch to “ON”, and
damage, be sure the water level is at least crank engine again after 10 seconds or
10 cm (4 in.) above the anti ventilation more.
plate. Do not try to crank after engine has
started.
 ENGINE OPERATION 47

This model is provided with start in gear 1. Shift lever

2. Neutral
protection.
ENON00010-0
3. Set the throttle grip to START position.
Note
4 3
Start-in-gear protection prevents engine
from starting at other than neutral shift. In-
gear starting of engine will move the boat
immediately, potentially leading to falling
down or causing passenger(s) to be thrown 2
overboard.
1
ENOM01710-0
Tiller handle type
1. Be sure to install the stop switch lock ENOF02339-0
to the stop switch, and attach the stop 1. Throttle grip
switch lanyard securely to the operator 2. START position
or to the operator's PFD (Personal Flo- 3. Fully closed
4. Fully opened
tation Device.)
4. Pull the choke knob fully.
7
1
1

ENOF02340-0

ENOF02337-0
1. Choke knob
1. Stop switch lock
ENON00501-0
2. Set the control lever in the Neutral
Note
position.
Choke is not necessary when the engine is
2
N warm. Set the throttle grip to “START” posi-
1 tion.

R F ENON00502-0

Note
If engine does not start with 4 or 5 times
starting operation, push the knob back and
restart.

ENOF02338-C
 48 ENGINE OPERATION

5. Pull the starter handle slowly until you

feel engagement, keep pulling till you
feel less resistance. Then pull it quickly.
repeat if necessary until started.
1 2

3 ENOF008691
1. Stop switch lock

2. Insert the main switch key.

ENOF02356-0
3. Set the control lever in the Neutral
position.
1. Slowly
2. Quickly 4. Raise the free throttle lever a little (both
3. Starter handle of cold engine and warm engine).
6. Check the cooling water from cooling ENON00504-0

7 water check port. Note

The free throttle lever can not be raised
when the control lever shift is in Forward or
Reverse.

1 2
N
F R
5

2 4
1
ENOF01911-0
3 6
1. Idle port
2. Cooling water check port 7
ENOF008701
1. Neutral (N)
ENOM01663-0
2. Control lever
Side mount RC type 3. Fully opened (Forward)
1. Be sure to install the stop switch lock 4. Fully opened (Reverse)
5. Free throttle lever
to the stop switch, and attach the stop 6. Main switch key
switch lanyard securely to the operator 7. Stop switch
or to the operator's PFD (Personal Flo-
tation Device.)
 ENGINE OPERATION 49

5. Turns the main switch key to START ENOM00042-B

position. Then, continuously push the

Emergency starting
ENOW00099-A
key to operate the choke.
ENON00503-0 WARNING
Note
When the emergency starter rope is used
Choke operation is not necessary if the for starting engine;
engine is warm. z Start in gear protection does not work.
Be sure to shift is at neutral position.
6. Stop pushing the key when the engine Otherwise the engine will move the boat
has started. immediately and cause personal injury.
The key returns to the original position, z Be careful that your clothes or other
items do not get caught in the rotating
automatically.
engine parts.
7. Returns the Free accel lever to close z To prevent accident and injury by rotat-
position. ing parts, do not re-attach flywheel
8. Check the cooling water from cooling cover and the top cowl after the engine
water check port. has been started.
z Do not pull starter rope if any bystander
ENON00035-A is behind. The action can injure the
Note bystander.
z Attach engine stop switch lanyard to
The free throttle lever can not be raised
when the control lever shift is in Forward or clothing or any part of body like arm 7
Reverse. before starting engine.

1. Remove the top cowl.

60/70

1
ENOF02378-0

1. Idle port ENOF02379-0

2. Cooling water check port
 50 ENGINE OPERATION

90, 115/140 90, 115/140

ENOF02382-0

ENOF02380-0

2. Remove the flywheel cover or recoil 3. Insert the knotted end of the starter
starter. rope into the notch in the flywheel and
60/70 EPTO wind the rope around the flywheel sev-
eral turns clockwise.

ENOF02392-0

70 MFG ENOF02390-0

4. Tie a loop in the another end of the

emergency starter rope and attach
socket wrench that is included in the
tool kit.
ENOW00860-0

CAUTION
ENOF02381-0 Be sure to keep the harness away from the
rotation parts.

5. Be sure to install the stop switch lock

to the stop switch, and attach the stop
switch lanyard securely to the operator
or to the operator's PFD (Personal Flo-
tation Device.)
 ENGINE OPERATION 51

6. Set the control lever in the Neutral 90, 115/140

position.
7. Pull the starter handle slowly until you
feel engagement, keep pulling till you
feel less resistance. Then pull it quickly. 1

ENOF02383-0

1. Choke plate

3. Raise the Free accel lever a little.

4. Turn the main switch key to start posi-
ENOF02391-0
tion.
5. Stop pushing the key when the engine
8. After engine starts, do not reinstall fly- has started.
wheel cover and top cowl. 6. Return the choke plate to open posi-
tion.
7
ENOM00518-0
ENOM0004B-0
If the choke solenoid fails to
operate (EP type only) 4. Warming up the engine
ENOW00932-0
1. Remove the top cowl.
2. Close the choke plate by finger. CAUTION
60/70 Be sure to check that cooling water is
coming out of the cooling water check port
during warm up.

Warm the engine at low engine speeds for

1 about
3 minutes : above 41°F (5 Υ )
5 minutes at 2000 min -1 (rpm) : above
41°F (5 Υ )
This allows the lubricating oil to circulate to
all parts of the engine. Operating the
ENOF02384-0 engine without warm up shortens the
engine's life.
 52 ENGINE OPERATION

1 ENOF009340
ENOF02378-0
1. Fully-open
1. Idle port 2. Fully-closed
2. Cooling water check port
ENOM00046-A
ENOM0004A-A
Engine speeds 5. Forward, reverse, and
Idling speed after warming up. acceleration
Idling speed Trolling speed
Model
(in Neutral) (in Forward ENOW00037-0

60/70
90 900 min-1 (rpm) 750 min-1 (rpm) WARNING
7 115/140
Before shifting into forward or reverse,
make sure that boat is properly moored
and outboard motor can be steered fully to
ENOM00972-0 the right and left. Make sure that no swim-
Free throttle lever (Side mount mer(s) is ahead or astern of the boat.
RC type)
ENOW00038-A
ENOW00956-0

WARNING
CAUTION
z Attach other end of emergency stop
z Keep the free throttle lever fully closed switch lanyard to the operator's PFD
position when start the engine. (Personal Flotation device) or arm and
z The free throttle lever is inoperative keep it attached during cruising.
unless the control lever is in neutral. z Do not attach the tether to a part of
z Also, the control lever is inoperative clothing that can be torn easily when
unless the free throttle lever is returned pulled.
to the fully-closed position. z Arrange the tether so that will not be
caught by any object when pulled.
The free throttle lever is for warm-up oper-
z Be careful not to pull the tether acciden-
ation.(Not required for engine starting) With tally during cruising. Unintentional stop
the control lever in neutral, move the free of engine can cause loss of control of
throttle lever upward to open the throttle. outboard motor. Rapid loss of engine
power can lead to falling down or caus-
 ENGINE OPERATION 53

ing passenger(s) to be thrown over- ENON00014-0

board. Note
Frequent shifting to forward or reverse can
ENOW00042-0
accelerate wear or degradation of parts. In
such case, replace gear oil earlier than the
WARNING period specified.
z Do not shift into Reverse during planing,
or control will be lost leading to serious ENOW00864-0

personal injury, boat may swamp, and/

or hull may be damaged. CAUTION
z Do not shift into Reverse during cruis- Do not increase engine speed unnecessar-
ing, or control may be lost, falling down ily when the shift is in neutral and reverse,
or causing passenger(s) to be thrown or engine damage may occur.
overboard. Leading to serious personal
injury, and steering system and/or shift- ENOM00890-B

ing mechanism may be damaged. Tiller handle type

ENOW00867-0
ENOW00861-0
WARNING
WARNING
Sudden acceleration and deceleration may
Do not shift at high boat speed, or control cause passenger(s) to be thrown over-

7
may be lost, falling down or causing pas- board or falling down.
senger(s) to be thrown overboard. Leading
to serious personal injury.
N
ENOW00862-0 1
CAUTION R F

Gear and clutch damage may occur if shift-

ing at high engine speed.
Engine must be in the slow idle position
before shifting is attempted.

ENOW00863-0
ENOF02338-0
CAUTION 1. Shift lever
Idle speed may be higher during warming Forward
up of engine. If shifted to Forward or 1. Turn the throttle grip to reduce engine
Reverse during warming up, it may be diffi- speed.
cult to shift back to neutral. In such case,
stop engine, shift to neutral, and restart 2. When the engine reaches trolling (or
engine to warm up. idling) speed, quickly pull the shift lever
to the Forward position.
Reverse
1. Turn the throttle grip to reduce engine
speed.
 54 ENGINE OPERATION

2. When the engine reaches trolling (or

idling) speed, quickly pull the shift lever
to the Reverse position. 7 8
Acceleration 2 7
ENOW00867-0 1 3
N
WARNING F R
6
Sudden acceleration and deceleration may
cause passenger(s) to be thrown over- 5
board or falling down.
4
Open throttle grip gradually.
ENOF008771

4 3 1. Forward (F)
2. Neutral (N)
3. Reverse (R)
4. Fully opened (Forward)
5. Fully opened (Reverse)
6. Free throttle lever
2 7. Control lever
8. Lock button

1 Forward
7 1. Quickly push the control lever to the
Forward (F) position 32°, where the
gear is connected, while lifting up on
ENOF02339-A the lock button located under the con-
1. Throttle grip trol lever grip.
2. Start position
3. Fully closed
2. Further forward motion will open the
4. Fully opened throttle.
Reverse
ENOM0900-0
Side mount RC type 1. Quickly pull the control lever to the
ENOW00867-0
Reverse (R) position at 32°, where the
gear is connected, while lifting up on
WARNING the lock button located under the con-
Sudden acceleration and deceleration may trol lever grip.
cause passenger(s) to be thrown over- 2. Further rearward motion will open the
board or falling down. throttle.
 ENGINE OPERATION 55

Acceleration
ENOW00867-A
4 3
CAUTION
Sudden acceleration and deceleration may
cause passenger(s) to be thrown over-
board or falling down. 2

Open control lever gradually. 1

ENOF02339-0
N
F R 1. Throttle grip
2. Start position
3. Fully closed
1 4. Fully opened

2. Put the shift lever in the Neutral posi-

tion.
ENOF008792 Run the engine for 2-3 minutes at
1. Control lever
ENOM00049-D
idling speed for cooling down if it has
been running at full speed.
7
6. Stopping the engine 3. Push the stop switch.

ENOW00868-0

WARNING
Be careful not to remove engine stop 1
switch lanyard from engine accidentally
while boat is running. Sudden stop of
engine can cause loss of steering control.
It can also cause loss of boat speed, possi-
bly leading the crew(s) and or objects on
the boat to be thrown forward due to iner-
tial force.
ENOF02338-B

Tiller handle type 1. Stop switch

1. Turn the throttle grip to the slow posi- Side mount RC type
tion. 1. Put the control lever in the Neutral
position and run the engine for 2-3
minutes at idling speed for cooling
down if it has been running at full
speed.
 56 ENGINE OPERATION

N
F R

1
1
2 2
ENOF008811

1. Control lever
ENOF02338-A
2. Mine switch key
1. Stop switch
2. Stop switch lock
2. Turn the main switch key to the OFF
position or push the stop switch. ( Do
not forget to turn the key off).

3 1
2
7 1

ENOF008711 ENOF00869A

1. ON 1. Stop switch
2. START 2. Stop switch lock
3. OFF
ENOM00910-0
ENOW00869-0 Spare emergency stop switch lock
(For CE marking model)
WARNING A spare emergency stop switch lock is
After stopping the engine: provided in the tool bag.
z Close the air vent screw on the fuel tank When used as described, the emergency
cap. stop switch clip and emergency stop
z Disconnect the fuel connector of the switch lanyard system stops the engine if
engine and the fuel tank.
z Disconnect the battery cord, after each
the operator falls away from the controls.
use. When an operator falls into water, be sure
to use emergency stop switch lock of the
Emergency engine stopping spare.
Remove stop switch lock to stop the Be sure to confirm the spare stop switch
engine. lock is in the tool bag before begin to oper-
ate.
 ENGINE OPERATION 57

ENOF00891-0

ENOM00920-0

7. Steering
ENOW00870-0

WARNING
ENOF00893-0
Sudden steering may cause passenger(s)
ENOM00050-0
to be thrown overboard or falling down.
8. Trim angle
Tiller handle type
Right turn ENOW00043-A
Move the tiller handle to the left
Left turn WARNING
Move the tiller handle to the right. z Adjust the trim angle when the engine is
stopped. 7
z Do not put hand or finger in between
outboard motor body and clamp bracket
when adjusting trim angle to prevent
injury in case the outboard motor body
falls.
z Unsuitable trim position can cause loss
of control of boat. When testing a trim
position, run boat slow initially to see if it
can be controlled safely.

ENOW00044-0

ENOF00892-0 WARNING
Remote control type Excessive trim up or down may lead to
Right turn unstable boat operation, potentially caus-
Turn the steering wheel to the right. ing the steering difficulty that leads to acci-
Left turn dent during cruising.
z Do not cruise at high speed if improper
Turn the steering wheel to the left.
trim position is suspected. Stop the boat
and readjust trim angle before continu-
ing cruise.
z For outboard motor model with PTT
switch on the bottom cowl, do not oper-
 58 ENGINE OPERATION

ate the switch during cruising, or control

of boat may be lost.

The trim angle of the outboard motor can

be adjusted to suit the transom angle of
the hull, and load conditions. Choose an
appropriate trim angle that will allow the
anti-ventilation plate to run parallel to the ENOF00053-0

water surface during operation.

ENOM00052-0 Trim angle adjustment

Proper trim angle The transom angle adjustment
The position of the thrust rod is correct if 1. Stop the engine
the hull is horizontal during operation. 2. Operate the Power Tilt switch or Gas
assisted tilt raise the outboard motor to
1 the tilt up position.
3. Lock the tilt with the Tilt stopper.
4. Change the trim lock pin position as
following picture.
7
ENOF00051-1

1. Perpendicular to the water surface

ENOM00053-0
Improper trim angle (bow rises too
high)
2
Set the thrust rod lower if the bow of the
boat rises above horizontal.

1
ENOF02350-0

1. Snap pin
2. Thrust rod
5. Reinstall the thrust rod securely.
ENOF00052-0
6. Operate the Power Tilt switch and
lower the outboard.
ENOM00054-A
Improper trim angle (bow dips into the
water)
Set the thrust rod higher if the bow of the
boat is below horizontal.
 ENGINE OPERATION 59

ENOM00060-A ENOM01712-0
Gas assist tilt type (70 MFG only)
9. Tilt up and down
Tilt up
ENOW00055-0
1. Pull the reverse lock lever upward until
it stops. (This is the tilt FREE position.)
WARNING 2. Now, tilt the outboard motor all the
Do not tilt up or down outboard motor way up.
when swimmer(s) or passenger is near to
prevent them from being caught between
outboard motor body and clamp bracket in
case the outboard motor body falls. 2

ENOW00048-0

WARNING 3 1

When tilting up or down, be careful not to

place your hand between the swivel
ENOF02353-0
bracket and the stern bracket.
Be sure to tilt the outboard motor down 1. Reverse lock lever
slowly. 2. Tilt up position (FREE)
3. Tilt down position (LOCK)
7
ENOW00056-A

WARNING
When tilting up outboard motor with fuel
joint for over a few minutes, be sure to dis-
connect fuel hose, or fuel may leak, poten-
tially catching fire.

ENOW00057-0

CAUTION ENOF02351-0

Do not tilt up outboard motor while engine 3. Push the reverse lock lever downward
operates, or no cooling water may be fed, until it stops.(this is the tilt LOCK posi-
leading to engine seizure due to overheat-
tion.)
ing.

ENON00921-0
Note
Before tilting the outboard motor up, after
stopping the motor leave it in the running
position for about a minute to allow water to
drain from inside the engine.
 60 ENGINE OPERATION

2 2

3 1 3 1

ENOF02353-0 ENOF02353-0

1. Reverse lock lever 1. Reverse lock lever

2. Tilt up position (FREE) 2. Tilt up position (FREE)
3. Tilt down position (LOCK) 3. Tilt down position (LOCK)
4. Lock the tilt with the Tilt stopper after
ENOM00069-A
the outboard motor has been tilted up.
Power Trim & Tilt type
Tilt up
1 1. Operate the Power Trim & Tilt switch
and tilt the outboard motor up.
2. Lock the tilt with the Tilt stopper after
7 the outboard motor has been tilted up
Tilt down
ENOF01319-0 1. Release the tilt stopper from the set-up
1. Tilt stopper position while slightly tilting up out-
ENOM01713-0 board motor.
Tilt down 2. Operate the Power Trim & Tilt switch
1. Release the tilt stopper.
and tilt the outboard motor down until
the motor touches to the thrust rod.
1
UP

DN
ENOF01319-0
ENOF000672
1. Tilt stopper
2. Pull the reverse lock lever upward until
it stops. (This is the tilt FREE position.) 1
3. Allow gravity to lower the outboard
motor.

4. Push the reverse lock lever downward

until it stops. ENOF01319-0
 ENGINE OPERATION 61

1. Tilt stopper manual relief valve is loosened in the "Man-

ual" direction.
The outboard motor can also be tilted up
and down using the switch provided under
the bottom cowl.

2
ENOF00679-0

1. POWER
2. MANUAL

ENOF02358-0 ENOM00068-A

It is possible to tilt up or down in spite of 10.Shallow water operation

main switch “ON” or “OFF”.

7
ENOW00051-0

ENOM00940-0
Manual relief valve WARNING
If the battery is dead, and the power tilt During shallow water operation, be careful
switch thus inoperative, open the manual not to place your hand between the swivel
valve completely in the Manual direction. bracket and the clamp bracket. Be sure to
This will allow manual tilting of the out- tilt the outboard motor down slowly.
board motor. ENOW00053-0
ENOW00872-0
CAUTION
WARNING
While in shallow water drive position, do
Make sure the manual relief valve is closed not operate the outboard motor in Reverse.
before operating the outboard motor. If the Operate the outboard motor at slow speed
manual relief valve is not closed, the out- and keep the cooling water intake sub-
board motor will tilt up when operated in merged.
reverse.
ENOW00054-0
ENOW00873-0
CAUTION
WARNING
Do not overtilt outboard motor when driv-
Before opening the manual relief valve, ing shallow water, or air may be sucked
make sure nobody is under the outboard through water inlet, potentially leading to
motor. If the outboard motor is in the tilted engine overheating.
up position, it will tilt down suddenly if the
 62 ENGINE OPERATION

1
ENOF01144-A

1. Water inlet

ENOM01714-0
Gas asisted tilt type
1. Close the throttle to reduce the engine
speed and shift into neutral.
2. Put the reverse lock lever in the FREE

7
position.

3 1

ENOF02353-0

1. Reverse lock lever

2. Tilt up position (FREE)
3. Tilt down position (LOCK)

3. Tilt the outboard motor up into desired

shallow water running position and put
the reverse lock lever in the LOCK
position.
 63
REMOVING AND CARRYING THE OUTBOARD MOTOR
ENOM00070-A

1. Removing the outboard motor

ENOW00890-A

WARNING
Before removing the outboard motor on the
boat, hang the outboard motor with the
hoist or equivalent device by attaching the
engine hanger to the outboard.
Use the hoist with allowable load is 250 kg
(550 lbs) or above.

ENOW00064-0

CAUTION
Engine may be hot immediately after oper-
ating and could cause burns if touched.
Allow engine to cool down before attempt-
ENOF02387-0
ing to carry the outboard.
ENOM00071-A
1. Stop the engine.
2. Remove the top cowl.
2. Carrying the outboard motor
3. Disconnect the fuel connector, the
8
ENOW00933-0
remote control cables and the battery
cords from the outboard motor. WARNING
4. Attach the hoist hooks to the engine Be sure to disconnect fuel connector
hanger. except when operating engine.
Fuel leakage is a fire or explosion hazard,
5. Remove the outboard motor from boat
which can cause serious injury or death.
and completely drain the water from
the gear case. ENOW00065-0

WARNING
Close air vent screw of fuel tank before
carrying or storing outboard motor and fuel
tank, or fuel may leak, potentially catching
fire.
 64 REMOVING AND CARRYING THE OUTBOARD MOTOR

ENOW00066-A ENOM00072-A

CAUTION 3. Trailering
Do not give a shock to an outboard motor ENOW00072-0
during transportation. It becames a cause
of breakage. CAUTION
Trailering in the tilted position may cause
damage to the outboard motor, boat, etc.
Keep the outboard motor in a vertical posi-
tion when carrying. ENOW00073-A
The optional outboard motor stand is rec-
ommended for keeping the outboard WARNING
motor vertical both during transport and Be sure to disconnect fuel connector
storage. except when operating engine.
Fuel leakage is a fire or explosion hazard,
which can cause serious injury or death.

ENOF00075-1

ENOW00068-0

8 WARNING
Close air vent screw of fuel tank and fuel
ENOF02361-0
cock before carrying or storing outboard
ENON00021-A
motor and fuel tank, or fuel may leak,
Note potentially catching fire.
z If the outboard motor must be laid down
ENOW00071-0
be sure drain the fuel and engine oil,
then the port side faces down as shown
in the following drawing.
CAUTION
z Elevate power unit 2 inches to 4 inches if The tilt support device supplied on your
traveling to avoid oil spillage. outboard motor is not intended for towing.
It is intended to support the outboard
motor while the boat is docked, beached,
etc.

When transporting a boat on a trailer with

the outboard motor still attached, discon-
nect the fuel line from the outboard motor
ENOF00680-0
beforehand and keep the outboard motor
in the normal running position or on a tran-
 REMOVING AND CARRYING THE OUTBOARD MOTOR 65

som saver bar.

Tiller handle type

To prevent the outboard motor from mov-
ing when it is attached on a boat during
transport on a trailer, properly tighten the
steering friction lever (page 66).

2 1

ENOF00073-A
1. Ground clearance should be provided sufficiently.
2. Transom saver bar
ENOW00067-0

WARNING
Do not go under outboard motor tilted up
even if it is supported by support bar, or
8
accidental fall of outboard motor could
lead to severe personal injury.
 66
ADJUSTMENT
ENOM00074-A
screw on the front of the remote control.
1. Throttle grip friction Turn clockwise to increase the friction and
counter-clockwise to decrease it.
70MFG type
ENOW00074-B Side mount type

WARNING
Do not overtighten the throttle adjustment
screw or it could result in difficulty of
movement resulting in the loss of control
causing an accident and could lead to
severe injury. 2
3
Friction adjustment of the throttle grip can 1
be made with the throttle adjustment
ENOF000782
screw.
1. Throttle friction adjustment screw
2. Lighter
3. Heavier

ENOM00076-0
2
3. Trim tab adjustment
1 3
ENOW00076-0

WARNING
z Be sure that outboard motor is secured
9 ENOF02363-0 to transom or service stand, or acciden-
1. Throttle friction adjustment screw tal drop or fall of outboard motor could
2. Lighter lead to severe personal injury.
3. Heavier z Be sure to lock outboard motor if it is
ENOM00075-0 tilted up, or accidental fall of outboard
motor could lead to severe personal
2. Remote control lever friction injury.
z Do not go under outboard motor tilted
ENOW00074-C
up and locked, or accidental fall of out-
WARNING board motor could lead to severe per-
sonal injury.
Do not overtighten the remote control
throttle friction adjustment screw or it ENOW00075-0

could result in difficulty of movement

resulting in the loss of control causing an WARNING
accident and could lead to severe injury. Inappropriate adjustment of trim tab could
cause steering difficulty. After installing or
To adjust the friction of the remote control
lever, turn the throttle friction adjustment
 ADJUSTMENT 67

readjusting trim tab, check if steering fic-

tion is even.

If straight-line cruising can not be

achieved, adjust the trim tab located under
the anti-ventilation plate.
z If the boat veers toward the left direct
the trim tab towards A (left from rear of
boat).
z If the boat veers toward the right direct
the trim tab towards B (right from rear of
boat).

1 1
ENOF00912-A 9
1. Trim tab
ENON00022-A
Notes
z After adjustment securely tighten the
trim tab fixing bolt.
z Check for looseness of the bolt and the
trim tab at regular intervals.
 68
INSPECTION AND MAINTENANCE
ENOM00077-0
Care of your outboard motor
To keep your outboard motor in the best
operating condition, it is very important
that you perform daily and periodic main-
tenance as suggested in the maintenance
schedules that follow.
ENOW00077-0

CAUTION
z Your personal safety and that of your
passengers depends on how well you
maintain your outboard motor. Carefully
observe all of the inspection and mainte-
nance procedures described in this sec-
tion.
z The maintenance intervals shown in the
checklist apply to an outboard motor in
normal use. If you use your outboard
motor under severe conditions such as
frequent full-throttle operation, frequent
operation in brackish water, or for com-
mercial use, maintenance should be per-
formed at shorter intervals. If in doubt,
consult your dealer for advice.
z We strongly recommend that you use
only genuine replacement parts on your
outboard motor. Damage to your out-
board motor arising from the use of
other than genuine parts is not covered
under the warranty.
10
 INSPECTION AND MAINTENANCE 69

ENOM0716-0

1. Daily inspection

Perform the following checks and inspec- ENOW00078-0

tion before and after use. WARNING

Do not use outboard motor if any abnor-
mality is found during pre-operation check
or it could result in severe damage to the
motor or severe personal injury.

Item Points to Check Remedy

• Check the amount of fuel in the tank. Replenish
Fuel System • Check for dust or water in the fuel filter. Clean
• Check rubber pipes for oil leakage. Replace *1
Lubrication • Check the amount of engine oil in the oil tank. Replenish
System • Check for dust or water in the oil filters. Clean
• Check the spark plugs for dirt, wear and carbon built-up. Clean or replace
Spark plugs NGK B8HS-10 or BR8HS-10 (1.0 mm gap) (0.0394 in)
• Check if the main switch functions normality. Remedy or replace *1
Electrical • Check if the battery electrolyte level and specific gravity are normal Replenish or recharge
Equipment • Check for loose connections on battery terminal. Retighten
• Check if the stop switch functions normally and make sure the lock Remedy or replace *1
plate is present.
• Check cords for loose connections and damage. Correct or replace *1
• Check that the choke solenoid and valve for the carburetor works Replace *1
Throttle normally.
System • Check if the carburetor and magneto work normally when turning the Correct *1
throttle grip, and also check links for looseness.
• Check if the clutch engages correctly when operating the Remote Adjust *1
Clutch and Control. (or Shift lever)
Propeller Sys-
• Check the propeller for bent or damaged blades. Replace
10
tem
• Check if the propeller nut is tightened and the split pin is present.
Installation of • Check all the motor installation bolts with the boat. Tighten
Motor • Check the thrust rod installation. Tighten
Power Trim & • Check working of the tilt up and down of the motor.
Tilt
• Check that cooling water is discharged from the cooling water check
Cooling Water
port after the engine has started.
• To be prepare tools and spare parts for replacing spark plugs, pro-
Tools and peller, etc.
Spares
• Check if the spare rope is provided.
Steering • Check working of steering handle and remote control.
Devices
• Check if the anode and trim tab are securely installed. Repair if necessary
Other parts
• Check the anode and trim tab for corrosion and deformation. Replace
*1 Have this handled by your dealer.
 70 INSPECTION AND MAINTENANCE

ENOM00082-A
Engine oil replenishing
1
ENOW00079-A 2
CAUTION
z Do not add engine oil of brand and grade
other than existing one. In case engine
oil of other brand or grade is added,
drain all oil and ask dealer for treatment.
z In case other than engine oil such as
gasoline is put in the oil chamber, empty 3
the chamber and ask dealer for treat-
ment.
z When replenishing engine oil, be careful
not to allow entry of foreign matters ENOF01963-0

such as dust and water into oil chamber. 1. Genuine of recommended engine oil
z Wipe off engine oil well immediately if 2. Filler lid
spilled and dispose of it in accordance 3. Oil tank cap
with local fire prevention and environ-
ENOM00083-A
ment protection regulations.
z Do not replenish engine oil over upper Washing outboard motor
limit. If overfilled, remove oil to upper ENOW00081-0

limit. If engine oil is over the upper limit,

it can leak potentially leading to engine WARNING
damage. Do not start engine without removing pro-
peller, or accidentally turning propeller
If the oil level is low, add recommended oil could cause personal injury.
to the oil tank.
1. Open the filler lid from the top cowl. ENOW00082-0

2. Open the oil tank cap WARNING

3. Fill the oil tank with the genuine engine
10 oil.
Never start or operate the engine indoors
or in any space which is not well ventilated.
4. After replenishing of the oil tank, be Exhaust gas contains carbon monoxide, a
sure to close the oil tank cap tightly. colorless and odorless gas which can be
fatal if inhaled for any length of time.

ENOW00920-0

CAUTION
When washing the outboard motor, be
careful not to spray the water inside of the
top cowl, especially electrical components.
 INSPECTION AND MAINTENANCE 71

ENON00026-0
Note
It is recommended to check chemical prop-
erties of water on which your outboard
motor is regularly used. 1

If outboard motor is used in salt water,

brackish water or water with a high acidic
level, use fresh water to remove salt, 2
chemicals or mud from exterior and cool-
ing water passage after every cruising or
before storing outboard motor for long
ENOF01325-A
time. Before flushing, remove the propeller
and the forward thrust holder. 1. Flushing attachment
2. Tape
.
ENOM00085-F
Flushing attachment
ENOW00922-0 1
CAUTION
To prevent the engine from starting when 1
you are near the propeller, remove the stop
switch lock.

1. Tilt down the outboard motor.

2
2. Remove the water plug from the gear ENOF01420-A
case, and screw in the flushing attach-
1. Flushing attachment
ment. 2. Water inlet
3. Attach the flushing attachment and
connect a water hose. Turn on the ENOM00085-A 10
Flushing by test tank
water and adjust the flow (Be sure to ENOW00081-0
seal the water inlet and sub-water inlet
(60/70 only), located in the gear case WARNING
with tape) Do not start engine without removing pro-
4. Put the shift lever in the neutral position peller, or accidentally turning propeller
and start the engine. could cause personal injury.

Continue flushing the outboard motor ENOW00082-0

for 3 to 5 minutes at idling.
5. Stop the engine and water supply.
WARNING
Remove the flushing attachment and Never start or operate the engine indoors
tape. After the flushing, be sure to reat- or in any space which is not well ventilated.
Exhaust gas contains carbon monoxide, a
tach the water plug.
 72 INSPECTION AND MAINTENANCE

colorless and odorless gas which can be

fatal if inhaled for any length of time. If a blown fuse is detected, try to deter-
ENOW00036-A
mine the cause for this and correct it. If the
cause for the problem is not corrected, the
CAUTION fuse will likely blow again.
When the engine is started in the test tank, If the fuse continues to blow, request an
to avoid over heating and water pump authorized Tohatsu dealer to inspect the
damage, be sure the water level is at least outboard motor.
10 cm (4 in.) above the anti ventilation
1. Stop the engine and disconnect the
plate.
And be sure to remove the propeller, when battery cable from the battery negative
starting the engine in the test tank. (See (-) terminal.
page 78) 2. Remove the engine cover.
Run the engine only at idling.
3. Remove the fuse box lid.
4. Remove the fuse and check it. If the
3 fuse is blown, replace it with a fuse of
the same specified rating. The out-
board motor is supplied with spare
1
fuses in the spare fuse holder.
60/70

2
ENOF00863-0

1. Test tank
2. Water
3. Over 10 cm (4 in.)

10
ENOM00950-0
Fuse replacement
ENOW00923-0

CAUTION
Before replacing a fuse, disconnect the
battery cable from the battery negative (-)
terminal. Failure to do so may cause a
short-circuit.
1
ENOW00924-0

CAUTION
ENOF02364-0
Never use a fuse with a rating that exceeds
1. Blown fuse
the specified rating as this could cause
serious damage to the electrical system.
 INSPECTION AND MAINTENANCE 73

90, 115/140

1
ENOF02347-0

1. Blown fuse

10
 74 INSPECTION AND MAINTENANCE

ENOM01717-0

2. Periodic inspection

It is important to inspect and maintain your outboard motor regularly. At each interval on
the chart below, be sure to perform the indicated servicing. Maintenance intervals should
be determined according to the number of hours or number of months, whichever comes
first.
For periodic inspection and maintenance, consult your servicing dealer.

Servicing Interval
Item 10 hours or 50 hours or
Every 100 Action Remarks
hours or 6
1 month 3 months
months

Carburetor *1 z z Strip, clean and adjust.

Adjust idling.

Fuel Fuel filter z z z Check and clean.

System
Piping z Check and clean.

Fuel tank z z z Clean

Check gaps.
Spark plugs z z z Remove carbon
0.9-1.0 mm
(0.035-0.039 in)
Ignition deposits.
Ignition
timing *1 z z Adjust timing.

Check for salt deposits

Starter
motor *1 z and battery cable
condition.
Starting
System Battery z z z Installation, fluid
quantity, gravity

Starter rope z z z Check for wear or

damage.

z z z Check for bend blades,

10
Propeller
damage, wear.
Change or replenish-oil
Lower
Unit
Gear oil z z z and check for water
leaks.

Water pump *1 z z Check for wear or

damage.
Replace impeller
every 12 months.

Bolt and Nuts z z z Re tighten.

Sliding and Rotating Parts

Grease Nipples z z Apply and pump in
grease.
Check power unit oil
Power Trim & Tilt *1 z z level and refill.
Check function of
manual release valve.
Oil Tank Check for leakage,
Engine
Oil Oil Pipe z z damage, position of
clips and filter
Repair or consult your
dealer
System*
Oil Filter conditions

Outer Equipment z z z Check for corrosion.

Anode z z Check for corrosion and

deformation.
Replace.

*1: Have this handled by your dealer

 INSPECTION AND MAINTENANCE 75

ENON00030-0

Note
Your outboard motor should receive careful, and complete inspection at 300 hours. This is the best
time for major maintenance procedures to be carried out.

ENOM00093-B ENOM00094-0
Fuel filters and fuel tank cleaning Fuel filter (for engine)
ENOW00093-A 1. Check in the cup for water and debris.
60/70
WARNING
Gasoline and its vapors are very flammable
and can be explosive.
Keep out of reach of children.
z Avoid repeated or prolonged contact
with skin or breathing of vapor.
z Do not start this procedure while engine
is operating or hot even after stopping it.
z Place fuel filter away from every source
of ignition such as sparks or open
flames.
z Wipe off gasoline well immediately if
ENOF02360-0
spilled and dispose of it in accordance
with local fire prevention and environ- 90, 115/140
ment protection regulations.
z Install fuel filter with all related parts in
place, or fuel leak could occur, leading
to catching fire or explosion.
z Check fuel system regularly for leakage.
z Contact authorized dealer for fuel sys-
tem services. Services by unqualified
person could lead to engine damage.

Water or dirt in the fuel tank will cause

10
engine performance problems.
Check and clean the tank at specified ENOF02365-0
times or after the outboard motor has
been stored for a long period of time (over
three months).
Fuel filters are provided inside the fuel tank
and engine.
 76 INSPECTION AND MAINTENANCE

1 6

2 1
3
4 2

5
ENOF00096-B

1. Body
2. O-ring
3. Filter
4. O-ring
5. Cup
6. Indication of Fuel Flow ENOF00926-1

2. If present, disconnect hoses from the 1. Fuel pick-up

fuel connector (male) and the fuel 2. Filter
ENOM00718-0
pump.
Engine Oil Line Cleaning
3. Remove the cup, filter and O-rings Oil filter and oil tank. Check the oil tank
from the fuel filter body. and/or filter for entrapped water and dust.
4. Check the wear and clogging for each 1. Disconnect all pipes between the oil
parts, and replace if necessary. tank and oil pump.
5. Remove fuel and any water or debris 2. Clean out foreign matter.
from the cup, filter and hoses. 3. Refit the pipes to the oil tank and
6. Reassemble all parts. pumps, and then fill up with new
10 ENOM00096-A
Fuel filter (for fuel tank)
engine oil.
4. For air purging, refer to Item No. 5:
1. Remove four screws to remove the Fuel and Engine Oil.
Fuel Pick-Up.
2. Clean the fuel filter and replace the
gasket.
3. Reassemble all parts.
 INSPECTION AND MAINTENANCE 77

z Do not go under outboard motor tilted

up and locked, or accidental fall of out-
board motor could lead to severe per-
sonal injury.

ENON00934-0
Note
1 Please dispose of used oil in a manner that
4 is compatible with the environment.
We suggest you take it in a sealed container
to your local service station for reclamation.
5 Do not throw it in the trash, pour it on the
ground or down a drain.

1. Tilt down the outboard motor.

2. Remove the oil plugs (lower and
upper), and completely drain the gear
oil into a pan.

2
6
3 ENOF02343-0

1. Engine oil tank

2. Check valve
3. Air vent screw
4.
5.
To carburetor
From fuel tank ENOF01332-0
10
6. Filter for engine oil
7. Pump for engine oil. 3. Insert the oil tube nozzle into the lower
oil plug hole, and fill with gear oil by
ENOM00098-B
Gear oil replacement squeezing the oil tube until oil flows out
ENOW00094-0
of the upper plug hole and bubbles is
disappeared to remove the air.
WARNING ENON00033-0

z Be sure that outboard motor is secured Note

to transom or service stand, or acciden- Use genuine gear oil or the recommended
tal drop or fall of outboard motor could one (API GL-5: SAE #80 to #90).
lead to severe personal injury. Required volume: 60/70 700mL (23.6 fl.oz)
z Be sure to lock outboard motor if it is 90/115/140 900mL (30.4 fl.oz)
tilted up, or accidental fall of outboard
motor could lead to severe personal
injury.
 78 INSPECTION AND MAINTENANCE

ENOW00928-0

CAUTION
Wipe off gear oil well immediately if spilled
and dispose of it in accordance with local
fire prevention and environment protection
regulations.

ENON00032-0
Note
If water in the oil, giving it a milky colored
appearance. Contact your dealer.

ENOF01334-0
ENOM00086-A

4. Install the upper oil plug, and then Propeller replacement

remove oil tube nozzle and install the ENOW00084-0

lower oil plug.

WARNING
z Do not begin propeller removal and
installation procedure with spark plug
caps attached, shift in forward or
reverse, main switch at other than
“OFF”, engine stop switch lock attached
to the switch, and starter key attached,
or engine could accidentally start lead-
ing to serious personal injury. Discon-
nect battery cable if possible.
z The propeller edge is thin and sharp.
Wear the groves during replacement to
protect your hands.

10 ENOF01332-0 ENOW00086-0

CAUTION
ENOW00095-0
z Do not install propeller without thrust
CAUTION holder, or propeller boss could be dam-
aged.
Do not reuse oil plug gasket. Always use z Do not reuse split pin.
new gasket and tighten oil plug properly to z After installing split pin, spread the pin
prevent entry of water into lower unit. apart to prevent it from falling out which
could lead to the propeller coming off
during operation.

A worn-out or bent propeller will lower the

motor's performance, and cause engine
trouble.
 INSPECTION AND MAINTENANCE 79

1. Put a piece of wood block between 6. Tighten the propeller nut to specified
propeller blade and anti-ventilation torque, and align one of grooves to
plate to hold propeller. propeller shaft hole.
Propeller nut torque:
35 Nm(25 ft-lb, 3.25kgf-m)
7. Install a new split pin into the nut hole
and bend it.

ENOF00084-B

ENOF00084-D
2. Remove the split pin, propeller nut and
washer. ENOM00087-A
3. Remove the propeller and thrust Spark plugs replacement
ENOW00087-0
holder.
4. Apply water proof grease to the pro- WARNING
peller shaft before installing a new pro-
z Do not reuse spark plug with damaged
peller. insulation, or sparks can leak through
5. Install the thrust holder, propeller, crack, potentially leading to electric
stopper, washer and propeller nut onto shock, explosion and/or fire.
the shaft. z Do not touch spark plugs immediately
after stopping engine as they will be hot
and could cause severe burns if
4 7 touched. Allow motor to cool down first.
6
5
ENOW00929-0 10
3
CAUTION
1
2 Use only the recommended spark plugs.
Spark plugs which have an different heat
ENOF01336-B range may cause engine damage.
1. Propeller
2. Thrust holder
If the spark plug(s) is fouled, has carbon
3. Bush build up, or is worn, it should be replaced.
4. Adapter
5. Washer
When reusing spark plugs, remove dirt
6. Propeller nut from the electrodes and adjust spark gap
7. Split pin
to specification.

1. Stop the engine.

 80 INSPECTION AND MAINTENANCE

2. Remove the top cowl. 60/70

3. Remove the spark plug caps.
4. Remove the spark plugs by turning it
counter-clockwise, using a 21 mm (13/
16 in) socket wrench and handle that is
provided in tool bag.
5. Inspect the spark plug. Replace the
spark plug if the electrodes are worn or
if the insulators are cracked or
chipped.
6. Measure the spark plug electrode gap
with a wire type feeler gauge. The gap
ENOF02366-0
should be 0.9-1.0 mm (0.035-0.039
inches). If the gap is different, replace 90,115/140
the spark plug with a new one
Use spark plug: B8HS-10 or BR8HS-
10

1
2 ENOF00085-0

1. Electrode
2. Spark gap (0.9–1.0 mm, 0.035–0.039 in)
ENOF02354-0

7. Install the spark plug by hand and turn

10 it carefully to avoid cross-threading.
8. Tighten the spark plug to the specified
torque.
ENON00028-0
Note
z Spark plug torque:
27.0 Nm (20 ft-lb) [2.7 kgf-m]
If a torque-wrench is not available when you
are fitting a spark plug, a good estimate of
the correct torque is 1/4 to 1/2 a turn past
finger-tight. Have the spark plug adjusted to
the correct torque as soon as possible with
a torque-wrench.
 INSPECTION AND MAINTENANCE 81

ENOM00088-A
Anode replacement
A sacrificial anode protects the outboard motor from electrolytic corrosion. Anode is
located on the gear case, cylinder etc.. When the anode is eroded more than 1/3 of origi-
nal size, replace it.
ENON00029-0
Notes
z Never grease or paint the anode.
z At each inspection re-tighten the anode attaching bolt. As it is likely to be subjected to electrolytic
corrosion.

*1 60/70 115/140

90

*1

90

10
*1

ENOF02367-0

*1: Handle by your dealer

 82 INSPECTION AND MAINTENANCE

ENOM00089-B 1. Oil cap

Power Tilt oil checking 2. Oil level
ENOW00088-0 Recommended oil
Use an automatic transmission fluid or
WARNING
equivalent.
z Be sure that outboard motor is secured Recommended oils are as shown below.
to transom or service stand, or acciden-
ATF Dexron III
tal drop or fall of outboard motor could
lead to severe personal injury.
z Be sure to lock outboard motor if it is Air purging from the Power Trim and
tilted up, or accidental fall of outboard Tilt unit.
motor could lead to severe personal Entrapped air in the Power Tilt unit will
injury.
cause poor tilting movement and
z Do not go under outboard motor tilted
up and locked, or accidental fall of out- increased noise.
board motor could lead to severe per- 1. With the outboard motor mounted on
sonal injury. the boat, set the manual release valve
to the Manual side, and tilt the out-
ENOW00089-A
board motor manually up/down 5-6
CAUTION times while checking the oil level.
Do not unscrew the oil cap with the out- 2. When done, close the valve by turning
board motor tilted down. Pressurized oil in it clockwise towards the Power side.
the oil tank may spurt out.

Check the oil level in the reservoir tank

while the tank is kept in a vertical position.
1. Tilt the outboard motor up and lock the 1
tilt with the tilt stopper.
2. Remove the oil cap by turning counter
clockwise, then check if the oil level
10 reaches the bottom line of the plug
hole. 2
ENOF00679-0

1. POWER
2. MANUAL

ENOF01340-0
 INSPECTION AND MAINTENANCE 83

ENOM00960-0
Grease point
Apply water proof grease to the parts shown below.

60/70

10

ENOF02368-0
 84 INSPECTION AND MAINTENANCE

ENOM00100-A
3. Drain all fuel from the fuel hoses, fuel
3. Off-season storage pump, fuel filter (See page 75) and
vapor separator (See page 85), and
ENOW00934-0
clean these parts.
WARNING Keep in mind that if gasoline is kept in
the carburetor for a long time, gum and
z Be sure to disconnect fuel connector
varnish will develop, causing the float
except when operating engine.
z Fuel leakage is a fire or explosion haz- valve to stick, restricting the fuel flow.
ard, which can cause serious injury or 4. Remove the spark plugs and put a tea-
death. spoon of engine oil or spray storage oil
into the combustion chamber through
ENOW00097-0
the spark plug holes.
WARNING 5. Turn the starter motor several times or
Be sure to use cloth to remove fuel remain- turn the starter motor to lubricate
ing in the cowl and dispose of it in accor- inside the cylinder.
dance with local fire prevention and ENOW00930-0
environment protection regulations.
WARNING
ENOW00096-0
z Be sure to remove stop switch lock to
CAUTION prevent ignited the spark plugs.
z Put a cloth to spark plug hole and wipe
Before servicing the motor for storage: up any spilled engine oil, when cranking
z Remove the battery cables. the outboard motor.
z Remove the spark plug caps from the
spark plugs. 6. Change the gear oil in the gear case
z Do not run the motor out of the water.
(See page 77).
Before you put your outboard motor in 7. Apply grease to grease point (See
storage, it is a good opportunity to have it page 83).
10 serviced and prepared by your dealer. 8. Stand the outboard motor up vertically
Be sure to use fuel stabilizer while running in a dry place.
the motor before storage. (See page 85)
ENOM00101-D
Engine
1. Wash the engine exterior and flush the
cooling water system thoroughly with
fresh water. Drain the water com-
pletely.
Wipe off any surface water with an oily
rag.
2. Remove the fuel hose from the out-
board motor.
ENOF02361-0
 INSPECTION AND MAINTENANCE 85

ENOW00066-0

CAUTION 1. Before adding fuel stabilizer additive,

drain the carburetor (See page 85).
Do not carry or store outboard motor in any
of positions described below.
2. Follow the instructions on the label
Otherwise, engine damage or property when adding the fuel stabilizer additive.
damage could result from leaking oil. 3. After adding the additive, let the out-
board motor run in the water for 10
minutes to make sure any old fuel in
the fuel system has been completely
replaced by the fuel with additive.
4. Turn the engine OFF
ENON00891-0
Note
If your motor is used occasionally, it is rec-
ENOF017270
ommended to use a good fuel stabilizer in
every tank of fuel and keep the container full
ENON00021-A to reduce condensation and evaporation.
Note
ENOM00970-A
z If the outboard motor must be laid down
Fuel system draining
be sure drain the fuel and engine oil,
ENOW00028-A
then the outboard motor on a cushion
as shown in the following drawing (See
page 64 and 85).
WARNING
z Elevate power unit 2 inches to 4 inches if For details on handling fuel, contact an
traveling to avoid air intrusion in the authorized dealer.
Power Trim and Tilt pump system.
Fuel and fuel vapors are extremely flamma-
ble and can be explosive.
z If fuel is spilled, wipe it up immediately.
z Keep the fuel tank well away from
sources of ignition, e.g. sparks or open
10
flames
z Perform all work outdoors or in a well
ventilated place.
ENOF00680-0
ENOW00097-0
ENOM00950-A
Adding a fuel stabilizer WARNING
When adding a fuel stabilizer additive
(commercially available), first fill the fuel Be sure to use cloth to remove fuel remain-
ing in the cowl and dispose of it in accor-
tank with fresh oil and fuel. If the fuel tank dance with local fire prevention and
is only partially filled, air in the tank can environment protection regulations.
cause the fuel to deteriorate during stor-
age.
 86 INSPECTION AND MAINTENANCE

1. Disconnect the fuel hose from the out- 90, 115/140

board motor.
2. Remove the top cowl.
3. Place an appropriate rag under the 1
drain screw.
4. Loosen the carburetor drain screw.
5. Leave the outboard motor until all fuel
has been drained.
6. When thoroughly drained, retighten the
drain screw securely.
7. Check the drained fuel for the pres-
ence of contaminants. If it either is ENOF02355-0
present, check the fuel filter and fuel in
the fuel tank. 1. Carburetor drain screw

60/70 ENOM00102-0
Battery
ENOW00931-A

WARNING
1 z Place the battery away from any source
of fire, sparks and open flames such as
burners or welding equipment.
z Place the battery away from fuel tank.
Accidental sparks of battery may cause
explosion of gasoline.

1. Disconnect the battery cables and be

sure to remove the negative terminal
10 first.
ENOF02370-0
2. Wipe off any chemical deposits, dirt, or
grease.
3. Apply grease to the battery terminals.
4. Charge the battery completely before
storing it for the winter.
5. Recharge the battery once a month to
prevent it from discharging and the
electrolyte from deteriorating.
6. Store the battery in a dry place.
 INSPECTION AND MAINTENANCE 87

ENOM00104-E
9. Run the engine for 10 minutes at half
4. Pre-season check throttle. The oil used for storage inside
the engine will be circulated out to
The following steps must be taken when assure optimum performance.
first using the engine after winter storage.
1. Check that the shift and throttle func- 5. Submerged outboard motor
tion properly. (Be sure to turn the pro-
ENOW00098-0
peller shaft when checking the shift
function or else the shift linkage may CAUTION
be damaged.)
Do not attempt to start submerged out-
2. Check the electrolyte level, and mea- board motor immediately after it is recov-
sure the voltage and specific gravity of ered, or engine could be severely
the battery. damaged.

Specific Gravity Terminal Voltage

Charge Condition After taking your outboard motor out of the
at 20° (V)
water, immediately take it to your dealer.
1.120 10.5 Fully discharged
The following are the emergency mea-
1.160 11.1 1/4 charged
sures to be taken for a submerged out-
1.210 11.7 1/2 charged
board motor, if you can not take it your
1.250 12 3/4 charged
dealer right away.
1.280 13.2 Fully charged
1. Wash the outboard motor with fresh
water to remove salt or dirt.
3. Check that the battery is secure and
2. Remove the spark plugs, and com-
the battery cables are properly
pletely drain the water from the engine
installed. by pulling recoil starter several times.
4. Fill the fuel tank with oil and fuel. 3. Inject a sufficient amount of engine oil
5. Connect the fuel line to the engine, and through the spark plug holes.
squeeze primer bulb.
6. Before starting the engine, disconnect
Pull the recoil starter rope several times
to circulate the oil throughout the out-
10
stop switch lock and crank approxi- board motor.
mately 10 pulling the recoil starter ENOM00106-A
(Manual start model) or 3times of 3sec.
6. Cold weather precautions
turning the starter motor (Electric start
model) in order to circulate the oil.
If you moor your boat in cold weather at
7. Start the engine and warm up the
temperatures below 0°C (32°F), there is
engine for 3 minutes in the “NEUTRAL”
the danger of remained water freezing in
position.
the cooling water pump, which may dam-
8. Run the engine for 5 minutes at the age the pump, impeller, etc. To avoid this
slowest speed. problem, submerge the lower half of the
outboard motor into the water.
 88 INSPECTION AND MAINTENANCE

ENOM00107-A

7. Striking underwater object

ENOW00935-0

CAUTION
Striking the sea bottom or an underwater
object may severely damage the outboard
motor.

Follow the procedure below and consult a

dealer as soon as possible.
1. Stop the engine immediately.
2. Check the control system, gear case,
boat transom etc.
3. Return to the nearest harbor slowly
and carefully.
4. Consult a dealer check the outboard
motor before operation again.

10 ENOF01145-0

ENOM00121-0

8. Operation with multiple

outboard motors

When operating the outboard motors in

reverse at more than the lowest speed, be
sure that all engines are running.
If any engine has stopped, be sure to tilt
the outboard motor up and keep its pro-
peller out of the water.
Otherwise, water could enter the engine
and cause damage to it.
 89
TROUBLESHOOTING
ENOM01719-0
If you encounter problem with the engine, check the list below and locate the problem you
are experiencing. Then follow the suggested remedies.
Do not hesitate to contact your dealer, as professionals advice and assistance is the best
way to keep the engine in optimum condition.
Engine Unstable
Abnor- Cannot Over-
engine Abnor- Power
Difficult starts. mally obtain
Poor running mally low heating Trim &
to start but high high
idling speed or
engine
engine
engine
of Tilt inop-
engine stops engine speeds erative
speed speeds engine
soon stops

z z z Empty fuel tank

Incorrect connection of
z z z z z z z fuel system

z z z z z z z Air enters fuel line

Deformed or damaged
z z z z z z z fuel pipe

Closed air vent on fuel

z z z z z z z tank cap

Clogged fuel filter, fuel

z z z z z z z pump or carburetor

Use of improper engine

z z z z z oil

Use of improper
z z z z z z gasoline

Excessive supply of
z z gasoline

Poor carburetor
z z z z z z z adjustment

Recirculation pipe
z z z z z z broken

11
Use of non-specified
z z z z z z z spark plugs

Dirt or carbon deposits

z z z z z z on spark plugs

No sparks or weak
z z z z z z sparks

Insufficient cooling
z z z z water flow

z z z z Faulty thermostat
 90 TROUBLESHOOTING

Engine Unstable
Abnor- Cannot Over-
engine Abnor- Power
Difficult starts. mally obtain
Poor running mally low heating Trim &
to start but high high
idling speed or
engine
engine
engine
of Tilt inop-
engine stops engine speeds erative
speed speeds engine
soon stops

z z z Propeller cavitation

Incorrect propeller
z z z z selection

Damaged or bent
z z z z z propeller

z z z z Unbalanced load in boat

z z z Transom too high

z z z Transom too low

Incorrect adjustment of
z z z z z z throttle link

Incorrect adjustment of
z z z z z z ignition timing

Insufficient battery
z capacity, loose
terminals, corrosion

Faulty ignition switch or

z Power Trim & Tilt switch

Remote Control lever

z not set to Neutral

Safety switch lock plate

z not fitted

Incorrect wiring
z z disconnected or broken
wire

z
11 Starter motor failure

Air in power trim & tilt

z z unit
 91
TOOL KIT AND SPARE PARTS
ENOM01720-0
The following a list of the tools and spare parts provided with the motor.
Name Quantity Remark
Tool Bag 1
Pliers 1
Socket Wrench 1 10 x 13 mm
Servicing Tools Socket Wrench 1 21 mm
Socket Wrench Handle 1
Screwdriver (Phillips-type and flat 1
head) Adapter-type
Emergency starter rope 1 1600 mm
Spare stop switch lock 1
Spare Parts *2
Spark Plug 1 NGK BR8HS-10 or B8HS-10
Split Pin 1 Diameter x Length = 3 x 25mm
Bracket Fixing Bolts 4 12mm
Bracket Fixing Nuts 4 12mm
Washers A, B 4 each A (large), B (small)
Fuel Tank (with primer bulb) 1 Removeable
Remote Control 1
Drag Link 1
Parts Packaged with Multi-purpose Meter 1 For 115/140
Engine *1 Meter Harness 1
Lead Wire for Meter 1
Remote Control 1
Drag Link 1
Tachometer 1 For 60/70, 90 EPTO
Trim meter 1
Lead Wire for Meter 1
*1 Not included as standard accessories in some markets.
*2 Three pieces for 70CX

12
 92
PROPELLER TABLE
ENOM01721-0
To ensure optimum performance, the propeller should match the boat type and its load.

Use a genuine propeller.

A propeller must be selected so that the engine min-1 (rpm) measured at wide open throt-
tle, while cruising, is within the recommended range.

60/70: . . . . . . . 5150 to 5850 min-1 (rpm)

90:. . . . . . . . . . 5000 to 5500 min-1 (rpm)
115/140: . . . . . 5200 to 5700 min-1 (rpm)

60/70 90
Pitch Pitch
Lighter load 21 Lighter load 21
19 19
17 17
15 15
13 13
11 11
Heavier load 9 Heavier load 9

115/140
Pitch
Lighter load 21
19
17
15
13
11
Heavier load 9

13
OWNER’S MANUAL

M 60C
M 70C
M 70CX
M 90A2
M 115A2
M 140A2 00311039EAH1 1804NB
Printed in Japan