M 2.5A2 M 3.5B2 M 3.5A2

OWNER’S MANUAL トーハツ船外機オーナーズマニュアル Original instructions

M2.5A2 M3.5A2 M3.5B2 OB No.003-11045-9AK1 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 © 2019 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. Please always keep this manual together with the outboard motor as a reference to everyone 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.

ENOM00113-0 EC DECLARATION OF CONFORMITY (DoC) This product conforms to certain portion of the European Parliament directive. DoC contains the following information; z Name and Address of the manufacturer. z Applied community directives z Reference standard z Description of the product. (Model name and serial number) z Signature of the responsible person (Name / Title / Date and place of issue).

ENON00937-0 Note For CE marked model The Outboard engine is intended to install on non-recreational craft within the European Union because it has not been confirmed compliance with requirement of Directive 2013/53/EU. 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 inquir- ies.

Serial Number:

ENOF02000-0 ENOF02001-0 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 thoroughly read and understand this Owner's Manual and carefully follow all of the instructions. Of particular importance is information preceded by the words “DANGER,” “WARNING,” “CAUTION,” and “Note.” Always pay special attention to such information to ensure safe operation of the outboard motor at all times.

ENOW00001-0 DANGER Failure to observe will result in severe personal injury or death, and possibly property damage.

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 ...... 14 4. LABEL LOCATIONS ...... 15 5. INSTALLATION ...... 18 1. Mounting the outboard motor on boat ...... 18 6. PRE-OPERATING PREPARATIONS ...... 20 1. Fuel handling ...... 20 2. Engine oil recommendation ...... 21 3. Fuel filling ...... 22 4. Break-In ...... 23 7. ENGINE OPERATION ...... 25 Before starting ...... 25 1. Fuel feeding ...... 25 2. Starting the engine ...... 26 3. Warming up the engine ...... 29 4. Forward, reverse, and acceleration ...... 29 5. Stopping the engine ...... 31 6. Steering ...... 32 7. Trim angle ...... 33 8. Tilt up and down ...... 34 8. REMOVING AND CARRYING THE OUTBOARD MOTOR...... 37 1. Removing the outboard motor ...... 37 2. Carrying the outboard motor ...... 37 3. Traillering ...... 38 9. ADJUSTMENT...... 39 1. Steering friction ...... 39 10. INSPECTION AND MAINTENANCE...... 40 1. Daily Inspection ...... 41 2. Periodic Inspection ...... 44 3. Off-season storage ...... 51 4. Pre-season check ...... 53 5. Submerged outboard motor ...... 54 6. Cold weather precautions...... 54 7. Striking underwater object ...... 54 8. Auxiliary outboard motor operation...... 54 11. TROUBLESHOOTING ...... 55 12. TOOL KIT AND SPARE PARTS ...... 56 13. PROPELLER TABLE ...... 58

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 8 MOTOR

9. ADJUSTMENT 9

10. INSPECTION AND MAINTENANCE 10

11. TROUBLESHOOTING 11

12. TOOL KIT AND SPARE PARTS 12

13. PROPELLER TABLE 13

1 10 GENERAL SAFETY INFORMATION

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

ENOW00005-0 WARNING SERIOUS INJURY IS LIKELY IF A PERSON IN THE WATER MAKES CONTACT WITH A MOVING BOAT, GEAR HOUSING, PROPELLER, OR ANY SOLID DEVICE RIGIDLY ATTACHED TO A BOAT OR GEAR HOUSING.

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 overboard. 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 FLOTATION DEVICE As the operator/driver and passenger of the boat, you are responsible to wear a PFD (Personal Flotation Device) while on the boat. GENERAL SAFETY INFORMATION 11

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

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 40). It is the operator's responsibility to perform all safety checks and to ensure that all lubrication and maintenance instructions are complied with for safe operation. Please comply with all instructions concerning lubrication and maintenance. You should take the engine to an authorized dealer or service shop for periodic inspection at the prescribed intervals. Correct periodic maintenance and proper care of this outboard motor will reduce the chance of problems and limit overall operating expenses.

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-B MODEL FEATURE

Model M2.5A2 M3.5A2 M3.5B2 2 Type MF MF MF

S z z z

Transom heights L z z z

Tiller Handle z z z

Remote Control

Separate fuel tank

Integral fuel tank z z z

Shifting z

Manual tilt z z z *1: Option

ENOM00811-B MODEL NAME EXAMPLE M3.5B2S

M 3.5 B 2 S

Product genera- Model description Horse power Minor change Shaft length tion

M (X)= Two stroke S= Short 15 in F= Four stroke - A and up 2 and up L= Long 20 in D= Two stroke DI UL= Ultra long 25 in SPECIFICATIONS 13

ENOM01300-0 2.5A2, 3.5A2, 3.5B2

Item MODEL 2.5A2 3.5A2 3.5B2 2 Overall Length mm (in) 550 (21.7) Overall Width mm (in) 345 (13.6) 220 (8.7) S mm (in) 955 (37.6) Overall Height L mm (in) 1082 (42.6) S mm (in) 435 (17.1) Transom Height L mm (in) 562 (22.1) S kg (lb) 12.5 (28) 13.0 (29) Weight L kg (lb) 13.0 (29) 13.5 (30) Output kW (ps) 1.8 (2.5) 2.6 (3.5) Max. Operating Range min-1 (rpm) 3,800-5,200 4,200-5,300 Trolling Speed in Forward Gear min-1 (rpm) 1,100 Idle Speed in Neutral Gear min-1 (rpm) -1,300 Engine Type 2-Stroke Number of Cylinders 1 Bore x Stroke mm (in) 47 x 43 (1.85 x 1.69) Piston Displacement mL (Cu in) 74.6 (4.55) Exhaust System Underwater exhaust Cooling System Forced water cooling Lubrication System Engine Oil Mixed Gasoline Starting System Manual starter Ignition System Flywheel Magneto C.D. Ignition Spark Plugs NGK BP6HS-10/BPR6HS-10 Trim Position 4 Unleaded regular gasoline : Pump posted 87 Octane Fuel (research octane rating of 91) Fuel Tank Capacity L (US gal) Approx. 1.4 (0.37) integral tank Engine Oil Genuine motor oil or recommended one (TCW-III) Fuel : Engine Oil Mixing Retio Unleaded Gasoline 50 : Genuine 2-stroke Engine Oil 1 Genuine Gear Oil or API GL5, SAE #80 to #90, Gear Oil mL (fl.oz) approx. 3.5B2:180 (6.1), 3.5A2 & 2.5A2:90 (3.0), Gear Shift Foward F-N Gear Reduction Ratio 1.85 (13 : 24) 2.15 (13 : 28) Operator Sound Pressure 81.8 (ICOMIA 39/94) dB (A) Hand Vibration Level 5.1 (ICOMIA 38/94) m/s2

Remark: Specifications subject to change without notice. Tohatsu outboard is power rated in accordance with ISO8655 (propeller shaft output). 14 PARTS NAME

ENOM01301-0 2.5A2, 3.5A2, 3.5B2

1 11 2 24 3 3 12 25 22 4 26

5 13 6 14 23 7 15

16 8 17 27 18

9 19 20 21 10 30

28 29

ENOF02002-0 1 Air Vent Screw 12 Shift Lever(3.5B2 only) 23 Tilt Stopper 2 Fuel Tank Cap 13 Handle Grip 24 Stop Switch 3 Top Cowl 14 Carring Handle 25 Carburetor Cover 4 Plug Cap Cover 15 Clamp Screw 26 Chork Lever 5 Fuel Cock 16 Thrust Rod 27 Drive Shaft Housing 6 Cooling Warter Check Port 17 Oil Plug (Upper) Grommet (3.5B2 only) 7 Clamp Bracket 18 Anti-Ventilation Plate 28 Steering Friction 8 Drive Shaft housing 19 Water Inlet (3.5B2 only) Adjustment Screw 9 Propeller 20 Gear Case 29 Spark Plug 10 Water Inlet (2.5/3.5A2) 21 Oil Plug (Lower) 30 Fuel Filter 11 Starter Handle 22 Throttle Lever 15 LABEL LOCATIONS

ENOM00019-A Warning label locations

2 1 4, 5

4 3

ENOF02003-1

1-1.Warning label urge to read the owner’s 2. Warning regarding fuel tank cap. (See manual. page20, 25) 1-2.Warning regarding stop switch (See page 32). 1 2

ENOF02050-0 3. Warning regarding high temperature.

314X67531-3

3GR-76191-0 16 LABEL LOCATIONS

4. Warning label urge to read the owner's manual.

3F0X72185-0 5. Warning regarding high temperature, 4 high voltage, rotating object.

314X72185-0 LABEL LOCATIONS 17

ENOM01001-0 Serial number label locations

O u t b o a r d M o to r 1) R a t e d P o w e r : 2) M a s s : 3) S e r i a l N o . 4) 4 5) 6)

Ma d e in J a p a n CAN ICES-2/NMB-2

ENOF02048-1

1. Model code(Model name) 2. Rated power 3. Dry mass weight 4. Serial No. 5. Manufacture name 6. Manufacture address

Description of serial number year code Last two digits of alphabet represent production year as below.

Year Code AK BX BA BB BC Year of 2019 2020 2021 2022 2023 manufacture

ENOM00024-B Keep the outboard motor in a vertical 1. Mounting the outboard position when mounting. motor on boat

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. Do not operate the outboard motor until it has been securely mounted on the boat in 5 ENOF02004-0 accordance with the instructions below.

ENOW00009-0 WARNING z Mounting the outboard motor without following this manual can lead to unsafe conditions such as poor maneuverability, 2 lack of control or fire. z Loose clamp screws and/or mounting 1 ENOF02005-0 bolts can lead to the release or displace- 1. Clamp Screw ment of the outboard motor, possibly 2. Tighten resulting in lost of control and/or serious

personal injury. Be sure that fasteners are ENOM00025-0 tightened to the specified torque (30 Nm Position ... Above keel line (3.0 kgf) 13 ft-lb). Check the fasteners for Place the outboard motor in the center tightness from time to time. z Be sure to use outboard mounting fasten- of the boat's transom. ers included in the outboard motor pack- 1 age 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 2 lift or hoist with sufficient capacity.

ENOF01141-0 1. Center of boat 2. Boat transom INSTALLATION 19

ENOM00026-0 ENOM00831-0 Transom matching Mounting the outboard motor Be sure that the anti ventilation plate of 1. Set the outboard motor to appropri- the outboard motor is 30–50 mm (1.2–2 ate position. in) below the bottom of hull. 2. Tighten the clamp screws by turning If the above condition cannot be met due their handles. to the shape of the bottom of your boat, 3. Secure the outboard motor to the please consult your authorized dealer. boat with a rope to prevent accidental loss of the outboard motor overboard.

ENON00930-0 1 Note 30−50 mm (1.2−2 in) Do not use tools to tighten clamp screws. 5 2 Over tightening could result in damage to the clamp screws and clamp brackets. ENOF01608-0

1. Bottom of hull ENON00002-0 2. Anti ventilation plate Note ENOW00007-0 A rope is not included in the standard CAUTION accessories. z Before beginning the running test, check that the boat with maximum capacity loading floats on the water in a proper attitude. Check the position of water surface on the driveshaft housing. If the water surface is near the bottom cowling, in high waves, water may enter the engine cylinders. z Incorrect outboard motor mounting height or existence of underwater object(s), such as hull bottom design, ENOF02006-0 bottom surface conditions or underwater accessories, can cause water spray possibly reaching the engine through an opening of the bottom cowling during cruising. Exposing the engine to such conditions for extended periods can lead to severe engine damage. 20 PRE-OPERATING PREPARATIONS

ENOM00030-A Some of these adverse effects are 1. Fuel handling caused because the ethanol in the gasoline can absorb moisture from the air, ENOW000017-0 resulting in a separation of the water/ CAUTION ethanol from the gasoline 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 mis- z Deterioration of rubber or plastic parts use 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 recom- 6 rily when using a major brand of unleaded mended to add a filter that has water gasoline meeting the following specifica- separating capability, and check the fuel tions: system for leaks and mechanical parts for USA and Canada — having a posted pump corrosion and abnormal wear more fre- Octane Rating of 87 (R+M)/2 minimum. quently. Premium gasoline (92 [R+M]/2 Octane) is And, in case any of such abnormality is also acceptable. Do not use leaded gaso- found, discontinue the use of such gasoline. line and contact our dealer immediately. Outside USA and Canada — Use If the outboard motor will only be used unleaded gasoline with declared octane infrequently, please see the remarks on rating of 91 RON or over. Use of premium fuel deterioration in the STORAGE chap- gasoline of 98 RON is also allowed. ter (P 51) for additional information.

ENOW00020-0 ENOM00032-A GASOLINES CONTAINING CAUTION ALCOHOL When operating a TOHATSU engine on gaso- The fuel system components on your line containing alcohol, storage of gasoline in TOHATSU engine will withstand up to 10% the fuel tank for long periods should be ethyl alcohol (hererinafter referred to as avoided. Long periods of storage, common the "ethanol"), content in the gasoline. to boats, create unique problems. In cars, But if the gasoline in your area contains alcohol blend fuels normally are consumed before they can absorb enough moisture to ethanol, you should be aware of certain cause trouble, but boats often sit idle long adverse effects that can occur. Increas- enough for phase separation to take place. ing the percentage of ethanol in the fuel In addition, internal corrosion may take can also worsen these adverse effects. place during storage if alcohol has washed PRE-OPERATING PREPARATIONS 21

protective oil films from internal components. Fuel by Oil Mixing (25:1, 50:1) Oil ENOW00018-0 1.0L (25:1) WARNING 25 : 1 0.5L 0.4L (10 :0.4) (25:0.5) Fuel leakage can cause fire or explosion, 50 : 1 0.2L potentially leading to severe injury or loss of (10 :0.2) life. Every fuel system part should be 0 2L10L 25L 30L checked periodically, and especially after Gasoline ENOF01708-0 long term storage, for fuel leak, change of hardness of rubber, expansion and/or corrosion of metals. In case any indication of fuel ENOM01003-A leakage or degradation of fuel part is found, Engine oil – gasoline mixing replace relevant part immediately before procedure continuing operation. ENOW00937-0 ENOM01002-0 CAUTION 2. Engine oil recommendation 6 z Do not use other than two stroke engine oil with specified grade, or the engine ENOW0002A-A may be damaged. CAUTION z Do not use fuel prepared in other than specified mixing ratio. Use of engine oils that do not meet these - Lack of engine oil can cause severe engine requirements will result in reduced engine trouble such as piston seizure. life, and other engine problems. - Excess of engine oil can shorten spark plug life, and/or cause increase of noxious Use a genuine engine oil or recom- exhaust. mended one (TCW3). Refer to your Dis- For quantities of engine oil and gasoline tributor. to be pre-mixed, refer to table in previ- Will not recommend use of other two ous page. stroke engine oil. When fuel tank built in the outboard Add engine oil into fuel oil tank. The mix- motors is used for operation: ing ratio with gasoline is 50 : 1 (50 parts 1 Prepare separate fuel container for gasoline and one part oil). Mix well by pre-mixing. hand. The mixing ratio during break-in 2 Pour engine oil into fuel container, and running is 25 : 1. then, gasoline. Mixing Ratio 3 Put cap on the container, and close tightly. Gasoline : Engine Oil 4 Shake the container to mix engine oil During break-in 25 : 1 and gasoline well and even. After break-in 50 : 1 5 Pour the mixture into fuel tank. 22 PRE-OPERATING PREPARATIONS

through air vent screw when it is open. Leak- ing gasoline is a dangerous fire hazard.

ENOW00028-A WARNING Consult an authorized dealer for details on handling gasoline, if necessary.

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

When carrying a fuel tank containing gasoline: z Close the fuel tank cap and air vent screw of fuel tank cap, or gasoline vapor will be emitted through the air vent screw, cre- ating a fire hazard. 6 z Do not smoke.

When or before refueling: z Be sure to remove the static electricity charged in your body before refueling. ENOF01709-B z The sparks due to static electricity may cause explosion of flammable gasoline. z Stop the engine, and do not start the ENON00922-0 Notes engine during refueling. z Do not smoke. z It is recommended to pre-mix by using z Be careful not to overfill fuel tank. Wipe separate fuel container. Attempting to up any spilled gasoline immediately. pre-mix in the integral fuel tank can make the mixture uneven. When or before cleaning the gasoline tank: z If integral fuel tank is used for mixing, z Dismount fuel tank from the boat. pour engine oil into the tank little by lit- z Place the fuel tank away from every tle while putting gasoline into the tank. source of ignition, such as sparks or open flames. z Do the work outdoors or in a well venti- ENOM00043-D lated area. 3. Fuel filling z Wipe off gasoline well immediately if spilled.

ENOW00019-0 After cleaning gasoline tank: WARNING z Wipe off gasoline well immediately if spilled. Do not fill the fuel tank over capacity. The z If the fuel tank is disassembled for clean- rise of gasoline temperature may cause gas- ing, reassemble carefully. Imperfect oline to expand which, if overfilled, may leak assembly may cause a fuel leak, possibly leading to fire or explosion. PRE-OPERATING PREPARATIONS 23

z Dispose aged or contaminated gasoline in accordance with local regulations. 1 ENOW00029-A WARNING When opening fuel tank cap, be sure to follow 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 tank is raised by heat from sources such as sun light. ENOF02008-0 1. Full line 1. Before opening fuel tank cap, turn air vent screw two turns counterclock- 4. After filling the tank, close the tank wise to release air pressure in the fuel cap. tank. ]ENOM00033-AB 6 4. Break-In

Your new outboard motor and lower unit 2 require break-in for the moving compo- 1 nents according to the conditions described in the following time table. Please refer to ENGINE OPERATION sec-

ENOF02007-0 tion (See page 25) to learn how to correctly start and operate the outboard 1. Two turns the air vent screw 2. Fuel tank cap motor. 2. Open the fuel tank cap slowly. ENOW00024-A 3. Fill the fuel not to over the shown WARNING level. Do not operate the outboard motor in closed area or area with no forced ventilation. Exhaust gas emitted by this outboard motor contains carbon monoxide that will cause death if inhaled continuously. Inhaling the gas initially causes symptoms such as feeling of sickness, drowsiness and headache. During operation of the outboard motor: z Keep peripheral area well ventilated. z Always attempt to stay on the windward side of emission. 24 PRE-OPERATING PREPARATIONS

ENOW00940-0 1–10 10 min – After 3–5 hrs min 3 hrs 5 hrs CAUTION Less Less Full Throttle z During the break-in period, never run the Idle than 1/2 than 3/4 throttle Position engine continuously at high speed. throttle throttle available z After running-in is completed, select the 2 4 correct propeller so that the engine 1 Approx. 3 Abailabl speed is the recommended range at the Crusing 500- Approx. e to wide-opon throttle. Speed at 3,500 4,000 operate z After completing 5 hours of breakin, minimu min-1 min-1 at wide replace the gear oil with new oil. Refer to m speed (rpm) (rpm) open max throttle “Changing the gear oil” in subsection (2), Periodic Inspection.

ENON00008-0 Note Proper break-in allows outboard motor to deliver it full performance for longer ser- 6 vice life. 4 3 2 1

ENOF02010-0

ENOW00023-0 CAUTION Operating the outboard motor without break-in can shorten service life of the product. If any abnormality is experienced during the break-in: z Discontinue the operation immediately. z Have the dealer check the product and take proper action(s) if necessary.

ENOM01004-0 Fuel mix ratio for break-in Gasoline 25: Genuine Engine Oil 1 25:1 when using genuine engine oil or the recommended one (TCW3). 25 ENGINE OPERATION

ENOM00042-0 Before starting

ENOW00022-B 2 CAUTION 1 Be sure to fill the engine before starting engine. (To properly fill the engine with oil follow the instructions. See page 21) ENOF02007-0 1. Two turns the air vent screw 2. Fuel tank cap 2. Open the fuel cock.

ENOF01710-B 7 1

ENOM00044-F 1. Fuel feeding ENOF02028-0 1. Fuel cock ENOW00937-0 ENOW00029-A CAUTION WARNING Be sure to close the fuel cock when the out- When opening fuel tank cap, be sure to fol- board motor is tilted up Otherwise, fuel low the procedure described below. Fuel could overflow. could blast out through the fuel tank cap in case the cap is loosened by using another procedure when internal pressure of fuel ENON00923-0 tank is raised by heat from sources such as Note sun light. If fuel is not supplied immediately to the carburetor (new engine or after cleaning), 1. Before opening fuel tank cap, turn air wait for about 15 seconds for the proper vent screw two turns counterclock- quantity of fuel to flow into the carburetor after opening the fuel cock. wise to release air pressure in the fuel tank. 26 ENGINE OPERATION

ENOM00045-D ENOW00032-B 2. Starting the engine CAUTION

ENOW00036-A Do not try to crank after engine has started. CAUTION ENOW00941-0 When the engine is started in the test tank, to avoid over heating and water pump dam- CAUTION age, be sure the water level is at least 10 cm (4 in.) above the anti ventilation plate. When the shift lever is at the “NEUTRAL” Run the engine only at idling. position, never move the throttle lever to medium or high speeds. This may cause seri- And be sure to remove the propeller, when ous damage to the engine by rotating it at starting the engine in the test tank. (See excessively high speed. (3.5B2) page 47) 1. Be sure to install the stop switch lock to the stop switch, and attach the 3 stop switch lanyard securely to the operator or to the operator's PFD (Personal Flotation Device.) 7 1

2 ENOF00863-0 1 1. Test tank 2. Water 3. Over 10 cm (4 in.)

ENOW00036-0

CAUTION ENOF02014-0 Be sure to stop engine immediately if cooling 1. Stop switch lock water check port is not discharging water, ENON00924-0 and check if cooling water intake is blocked. Note Operating engine could lead to overheating potentially leading to engine damage. Con- The engine will not start if the lock is in released condition. sult an authorized dealer if the cause cannot be found. ENGINE OPERATION 27

2. Set the shift lever in the Neutral posi- ENON00502-0 tion. (3.5B2 only) Note If engine does not start with 4 or 5 times starting operation, push the knob back and 1 restart.

5. Pull the starter handle slowly until you feel engagement, keep pulling till you feel less resistance. Then pull it ENOF02015-0 quickly. repeat if necessary until 1. Shift lever started. 3. Set the throttle lever to the Start 1 2 position.

ENOF02016-0 ENOF02018-0

1. Throttle lever 1. Slowly 4. Set the choke lever to the Close posi- 2. Quickly tion. ENON00926-0 Note Return the recoil starter grip slowly when the engine has started. Releasing the starter grip at the extended position may cause a trouble in the starting system.

ENON00927-0 1 Note In cold weather, pull the starter handle 2 or 2 ENOF02017-0 3 times while moving up the choke lever to 1. Close choke the engine. 2. Open ENON00501-A Note Choke is not necessary when the engine is warm. 28 ENGINE OPERATION

6. When the engine has started, imme- z Attach engine stop switch lanyard to diately return the choke lever to the clothing or any part of body like arm Open position then move the throttle before starting engine. lever downward to slow speed. 1. Remove the top cowl fixing bolts, to remove the top cowl.

2 ENOF02017-0 1. Close 2. Open ENON00928-0

Note ENOF02019-0 2. Remove the three bolts fastening the If the engine stops soon after having been started with the choke lever at the Close recoil starter. position, set the choke lever to the Open 3. Remove the recoil starter. 7 position and perform the starting procedure again.

ENOM00042-D Emergency starting

ENOW00099-A WARNING When the emergency starter rope is used for starting engine; ENOF02020-0 z Start in gear protection does not work. Be 4. Insert the knotted end of the starter sure to shift is at neutral position. Other- rope into the notch in the flywheel wise the engine will move the boat imme- and wind the rope around the fly- diately and cause personal injury. z Be careful that your clothes or other wheel several turns clockwise. items do not get caught in the rotating 5. Tie a loop in the another end of the engine parts. emergency starter rope and attach z To prevent accident and injury by rotating socket wrench that is included in the parts, do not re-attach flywheel cover tool kit. and the top cowl after the engine has been started. 6. Set the control lever in the Neutral z Do not pull starter rope if any bystander is position. behind. The action can injure the bystander. ENGINE OPERATION 29

7. Pull the starter handle slowly until you 1. Cooling water check port feel engagement, keep pulling till you ENOM00044-B feel less resistance. Then pull it Engine speeds quickly. Idling speed after warming up. Trolling speed Idling speed Model (in Forward) (in Nutral) 1,100 min-1 2.5A2 - (rpm) 1,100 min-1 3.5A2 - (rpm) ENOF02021-0 1,100 min-1 1,300 min-1 3.5B2 8. After engine starts, do not reinstall (rpm) (rpm) flywheel cover and top cowl. ENOM00046-A ENOM00043-C 4. Forward, reverse, and 3. Warming up the engine acceleration

ENOW00932-0 ENOW00037-0 CAUTION WARNING Be sure to check that cooling water is com- Before shifting into forward or reverse, make 7 ing out of the cooling water check port dur- sure that boat is properly moored and out- ing warm up. board motor can be steered fully to the right and left. Make sure that no swimmer(s) is Warm the engine at low engine speeds ahead or astern of the boat. for about ENOW00038-A 3 minutes : above 5°C (41°F) 5 minutes at 2000 min-1 (rpm) : WARNING above 5°C (41°F) z Attach other end of emergency stop This allows the lubricating oil to circulate switch lanyard to the operator's PFD (Per- to all parts of the engine. Operating the sonal Flotation device) or arm and keep it engine without warm up shortens the attached during cruising. z Do not attach the tether to a part of engine's life. clothing that can be torn easily when pulled. z Arrange the tether so that will not be caught by any object when pulled. z Be careful not to pull the tether accidentally during cruising. Unintentional stop of engine can cause loss of control of outboard motor. Rapid loss of engine power 1 can lead to falling down or causing passenger(s) to be thrown overboard.

ENOF02022-0 30 ENGINE OPERATION

ENOW00861-0 ENOM00890-B Tiller handle type

WARNING ENOW00867-0 Do not shift at high boat speed, or control may be lost, falling down or causing passen- WARNING ger(s) to be thrown overboard. Leading to Sudden acceleration and deceleration may serious personal injury. cause passenger(s) to be thrown overboard or falling down. ENOW00862-0 CAUTION ENOW00865-A Gear and clutch damage may occur if shifting CAUTION at high engine speed. Do not force to shift when the throttle grip is Engine must be in the slow idle position not in the fully closed position, otherwise, before shifting is attempted. steering system and/or shifting mechanism may be damaged. ENOW00863-0

ENOW01303-0 CAUTION Forward (3.5B2 only) Idle speed may be higher during warming up of engine. If shifted to Forward or Reverse 7 during warming up, it may be difficult to shift back to neutral. In such case, stop engine, shift to neutral, and restart engine to warm up. 2 3 ENON00014-0 Note Frequent shifting to forward or reverse can accelerate wear or degradation of parts. In such case, replace gear oil earlier than the 1 ENOF02023-0 period specified. 1. Shift lever 2. Neutral (N) 3. Forward (F) ENOW00864-0 CAUTION Do not increase engine speed unnecessarily when the shift is in neutral and reverse, or engine damage may occur. ENGINE OPERATION 31

Forward 1. Lower the throttle lever in order to 3 reduce engine speed. 2. When the engine reaches trolling (or 1 2 idling) speed, quickly pull the shift lever to the Forward position. Reverse 1. Lower the throttle lever in order to ENOF02025-0 reduce engine speed. 1. Throttle lever 2. Fully closed 2. When the engine reaches trolling (or 3. Fully opened idling) speed, quickly pull the shift lever to the Neutral position. ENOM00049-C 3. The handle upright, turn the outboard 5. Stopping the engine motor at an angle of 180° and quickly ENOW00868-0 turn the shift lever to the Forward (F) side. (3.5B2 only needs to operate WARNING shift lever) Be careful not to remove engine stop switch lanyard from engine accidentally while boat is running. Sudden stop of engine can cause 7 loss of steering control. It can also cause loss of boat speed, possibly leading the crew(s) and or objects on the boat to be thrown forward due to inertial force. Tiller handle type 1. Lower the throttle lever in order to the slow position. ENOF02024-0 Acceleration ENOW00867-0 1 WARNING 2 Sudden acceleration and deceleration may cause passenger(s) to be thrown overboard or falling down. ENOF02026-0 1. Throttle lever The speed is controlled by operating the 2. Fully closed throttle lever. Moving the throttle lever graduaally upward increases the speed, 2. Put the shift lever in the Neutral posi- and moving it downward decreases the tion. (3.5B2 only) speed. Run the engine for 2-3 minutes at idling speed for cooling down if it has been running at full speed. 32 ENGINE OPERATION

3. Push the stop switch.

1 1 2 2

ENOF02029-0 ENOF02027-0 1. Stop switch 1. Stop switch 2. Stop switch lock 2. Stop switch lock

ENOM00910-0 4. Close the air vent screw and fuel Spare emergency stop switch lock (For cock. CE marking model) A spare emergency stop switch lock is 2 provided in the tool bag. When used as described, the emergency stop switch clip and emergency stop switch lanyard system stops the engine if 7 the operator falls away from the controls. When an operator falls into water, be sure to use emergency stop switch lock of the spare. 1 Be sure to confirm the spare stop switch lock is in the tool bag before begin to ENOF02030-A operate. 1. Fuel cock 2. Air vent screw

ENOW00869-0 WARNING ENOF00891-0 After stopping the engine: z Close the air vent screw on the fuel tank ENOM00920-0 cap. 6. Steering z Disconnect the fuel connector of the engine and the fuel tank. ENOW00870-0 z Disconnect the battery cord, after each use. WARNING

Emergency engine stopping Sudden steering may cause passenger(s) to be thrown overboard or falling down. Remove stop switch lock to stop the engine. ENGINE OPERATION 33

Tiller handle type and readjust trim angle before continuing Right turn cruise. Move the tiller handle to the left z For outboard motor model with PTT switch on the bottom cowl, do not oper- Left turn ate the switch during cruising, or control Move the tiller handle to the right. 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 water surface during operation.

ENOM00052-0 Proper trim angle The position of the thrust rod is correct if ENOF00892-0 the hull is horizontal during operation. ENOM00050-0 7. Trim angle 1 7 ENOW00043-A WARNING z Adjust the trim angle when the engine is stopped. ENOF00051-1 z Do not put hand or finger in between outboard motor body and clamp bracket 1. Perpendicular to the water surface when adjusting trim angle to prevent

injury in case the outboard motor body ENOM00053-0 falls. Improper trim angle (bow rises too z Unsuitable trim position can cause loss of high) control of boat. When testing a trim posi- Set the thrust rod lower if the bow of the tion, run boat slow initially to see if it can boat rises above horizontal. be controlled safely.

ENOW00044-0 WARNING Excessive trim up or down may lead to unsta- ble boat operation, potentially causing the steering difficulty that leads to accident during cruising. ENOF00052-0 z Do not cruise at high speed if improper trim position is suspected. Stop the boat 34 ENGINE OPERATION

ENOM00054-0 Improper trim angle (bow dips into the water) Set the thrust rod higher if the bow of the boat is below horizontal.

1 ENOF01612-0

ENOF00053-0 1. Push in 2. Pull out Manual Tilt type 5. Reinstall the thrust rod in the desired position securely. 6. Gentry tilt down the outboard motor.

ENOM00060-A 8. Tilt up and down 7 ENOW00055-0 WARNING Do not tilt up or down outboard motor when swimmer(s) or passenger is near to prevent 1 2 them from being caught between outboard 3 motor body and clamp bracket in case the ENOF00229-0 outboard motor body falls. 1. Thrust rod 2. Higher ENOW00048-0 3. Lower WARNING Trim angle adjustment (Manual tilt type) When tilting up or down, be careful not to The transom angle adjustment place your hand between the swivel bracket and the stern bracket. 1. Stop the engine. Be sure to tilt the outboard motor down 2. Shift into neutral position (3.5B2 only) slowly. 3. Tilt up the outboard motor. 4. Remove the thrust rod by pressing clip as shown picture. ENGINE OPERATION 35

ENOW00057-0 CAUTION Do not tilt up outboard motor while engine operates, or no cooling water may be fed, leading to engine seizure due to overheating. 1

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. ENOF02031-0

1. Tilt stopper ENOM00222-A Tilt up ENOM01304-0 1. Close the fuel cock and tighten the air Outboard motor position in tilt up vent screw of the tank cap. When the outboard motor is in the tiltup 2. Fully tilt up the outboard motor. position, the tilt handle side must be in 3. Press in the tilt stopper. the upward direction. Tighten the steer- 4. Gently lower the outboard motor to ing friction adjustment screw to keep 7 rest on the tilt stopper. the direction.

2 1 CORRECT

1 ENOF02032-1

ENOF02030-A 1. Tilt handle 1. Fuel cock 2. Starter handle 2. Air vent screw 36 ENGINE OPERATION

INCORRECT

ENOF02033-1

ENOM00223-A Tilt down 1. Fully tilt up the outboard motor. 2. Pull out the tilt stopper. 3. Gently tilt down the outboard motor.

ENOF02034-0 1. Tilt stopper 37 REMOVING AND CARRYING THE OUTBOARD MOTOR

ENOM00070-B ENOW00066-1 1. Removing the outboard CAUTION motor z Do not give a shock to an outboard motor during transportation. It becames a cause ENOW00064-B of breakage. CAUTION z Do not carry or store outboard motor in any of positions described below. Engine may be hot immediately after operat- Otherwise, engine's exterior parts may be ing and could cause burns if touched. Allow damaged or water may enter the cylinder engine to cool down before attempting to through the exhaust port and cause carry the outboard. engine problems. 1. Stop the engine. 2. Be sure to close the air vent and the fuel cock. 3. Remove the outboard motor from boat and completely drain the water from the gear case.

ENOF02035-0

Keep the outboard motor in a vertical 8 position when carrying. The optional outboard motor stand is recommended for keeping the outboard motor vertical both during transport and storage.

ENOF02004-0

ENOM00071-A 2. Carrying the outboard motor

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.

ENOF02036-0 38 REMOVING AND CARRYING THE OUTBOARD MOTOR

ENON00021-C fully down. Trailering in the tilted position Note may cause damage to the outboard motor, If the outboard motor must be laid down, boat, etc. be sure drain the fuel from the fuel line If trailering with outboard motor fully down and carburetor in advance, then the port is not available (the gear case skeg is too side face down on the cushion as shown close to the road in a vertical position), fix in the drawing. the outboard motor securely using a device (like a transom saver bar) in the tilted position.

When transporting a boat on a trailer with the outboard motor still attached, disconnect the fuel line from the out- 1 board motor beforehand and keep the ENOF02037-0 outboard motor in the normal running 1. Handle position or on a transom saver bar. ENOM00072-A 3. Traillering Tiller handle type To prevent the outboard motor from ENOW00072-0 moving when it is attached on a boat CAUTION during transport on a trailer, properly tighten the steering friction screw Trailering in the tilted position may cause (page 39). 8 damage to the outboard motor, boat, etc. ENOW00068-0 WARNING Close air vent screw of fuel tank and fuel cock before carrying or storing outboard motor and fuel tank, or fuel may leak, potentially catching fire. 2 ENOW00071-0 1

CAUTION ENOF00074-B 1. Ground clearance should be provided The tilt support device supplied on your out- sufficiently. 2. Transom saver bar board motor is not intended for towing. It is intended to support the outboard motor ENOW00067-0 while the boat is docked, beached, etc. WARNING ENOW00072-A Do not go under outboard motor tilted up even if it is supported by support bar, or CAUTION accidental fall of outboard motor could lead When trailering the outboard motor should to severe personal injury. be in a vertical (normal running) position, 39 ADJUSTMENT

ENOM00073-E 1. Steering friction

ENOW00074-E WARNING Do not overtighten the steering friction adjustment screw it could result in difficulty of movement resulting in the loss of control causing an accident and could lead to severe injury.

ENON0506-0 Note The steering friction adjustment screw is used to adjust the friction load of the steering, but not to fix the steering. Excess tightening of the adjustment screw may cause damage to the swivel bracket.

Steering friction can be adjusted in accordance with your preference by turning the steering friction adjustment screw.

1 9

2 3

2 3 ENOF02038-0 1. Steering friction adjustment screw 2. Heavier 3. Lighter 40 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 maintenance 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 maintenance procedures described in this section. 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 outboard motor arising from the use of other than genuine parts is not covered under the 10 warranty. INSPECTION AND MAINTENANCE 41

ENOM01305-0 1. Daily Inspection

Perform the following checks before and ENOW00078-0 after use. WARNING Do not use outboard motor if any abnormality 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 debris in the fuel filters. Clean or Replace • Check the rubber hoses for fuel leakage. Replace *1 • Check for crack, leakage, damage in the fuel tank cap. Replace Fuel Tank Cap • Check for crack, damage in the gasket and tether. Replace • Check for leakage at full close. Replace • Check that the stop switch functions normally and make sure Remedy or replace *1 Electrical the lock plate is in right location. Equipment • Check cords for loose connections and damage. Correct or replace *1 • Check the spark plug for dirt, wear and carbon build-up. Clean or replace *1 • Check that the carburetor choke valve functions normally. Replace *1 Throttle System • Check carburetor linkage is working normally when moving the Correct *1 throttle lever. • Check the rope for wear and chafing. Replace *1 Recoil Starter • Check the ratchet engagement. Correct or replace *1 • Check that the clutch engages correctly when operation the Adjust *1 Clutch and shift lever. (3.5B only) Propeller Sys- • Visually check the propeller and shear pin for bent or damaged Replace tem blades. • Check that the split pin is on the propeller. 10 • Check the clamp screws attaching the motor to the boat for Tighten Installation of tightness. Motor • Check the thrust rod installation. Tighten • Check that cooling water is discharged from the cooling water Repair *1 Cooling Water check port after the engine has started. • Check that there are tools and spare parts for replacing spark Tools and plugs, the propeller, etc. Spares • Check that you have the spare rope. • Check if the anode is securely installed. Repair if necessary Other parts • Check the anode for corrosion and deformation. Replace *1 Have this handled by your dealer. 42 INSPECTION AND MAINTENANCE

ENOM00083-0 ENOM00085-B Washing outboard motor Flushing attachment (3.5B2 only) ENOW00922-0 ENOW00081-0 WARNING CAUTION Do not start engine without removing pro- To prevent the engine from starting when peller, or accidentally turning propeller you are near the propeller, remove the stop could cause personal injury. switch lock.

ENOW00082-0 1. Tilt down the outboard motor. WARNING 2. Remove the water plug from the drive Never start or operate the engine indoors or shaft housing, and screw in the flush- in any space which is not well ventilated. ing attachment. Exhaust gas contains carbon monoxide, a 3. Attach the flushing attachment and colorless and odorless gas which can be fatal if inhaled for any length of time. connect a water hose. Turn on the water and adjust the flow. Continue ENOW00920-0 flushing the outboard motor for 3 to 5 CAUTION minutes. 4. After the flushing, be sure to reattach When washing the outboard motor, be care- the water plug. ful not to spray the water inside of the top cowl, especially electrical components. 5. Tilt up the outboard motor. . ENON00026-0 Note It is recommended to check chemical properties of water on which your out- 1 board motor is regularly used. 10 If outboard motor is used in salt water, brackish water or water with a high acidic level, use fresh water to remove salt, 1 chemicals or mud from exterior and cooling water passage after every cruising or before storing outboard motor for long time. Before flushing, remove the

propeller and the forward thrust holder. ENOF02040-0

1. Flushing attachment (option) INSPECTION AND MAINTENANCE 43

ENOM00085-A Flushing by test tank ENOW00081-0 WARNING Do not start engine without removing propeller, or accidentally turning propeller could cause personal injury.

ENOW00082-0 WARNING Never start or operate the engine indoors or in any space which is not well ventilated. Exhaust gas contains carbon monoxide, a colorless and odorless gas which can be fatal if inhaled for any length of time.

ENOW00036-A CAUTION When the engine is started in the test tank, to avoid over heating and water pump damage, be sure the water level is at least 10 cm (4 in.) above the anti ventilation plate. And be sure to remove the propeller, when starting the engine in the test tank. (See page 47)

3 10 1

ENOF00863-0 1. Test tank 2. Water 3. Over 10 cm (4 in.) 44 INSPECTION AND MAINTENANCE

ENOM01306-0 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.

Servicing Interval

Item 10 hours 50 hours Every 100 Action Remarks or or hours or 1 month 3 months 6 months Carburetor *1 z Clean, and adjust. Fuel filter zzzCheck and clean or Replace. Fuel System Piping/Hose z Check and Replace. Fuel tank zzzClean. Check gaps. Remove carbon 0.9–1.0 mm Ignition Spark plugs zzz deposits or Replace. (0.035–0.039 in) Starting Starter rope zzzCheck for wear or chafting. System Check for bent blades, damage, Propeller zzz wear. Shear pin & zzzCheck and Replace. Split pin Lower Unit 180 mL (6.1 fl.oz.) Replace or Fill gear oil and check : 3.5B2 Gear oil zzz for water leaks. 90ml (3.0 fl.oz.) : 2.5A2/3.5A2 Water pump *1 z Check for wear or damage. 10 Bolt and Nuts zzzRetighten. Sliding and Rotating Parts. zzApply and pump in grease. Grease Nipples Outer Equipment zzzCheck for corrosion. Check for corrosion and Anode zz deformation.

*1: Have this handled by your dealer.

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. INSPECTION AND MAINTENANCE 45

ENOM00093-A Fuel filters and fuel tank cleaning

ENOW00093-B 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 1 skin or breathing of vapor. 2 z Do not start this procedure while engine is operating or hot even after stopping it. 3 z Place fuel filter away from every source of ignition such as sparks or open flames. z Wipe off gasoline well immediately if ENOF02047-0 spilled and dispose of it in accordance 1. Fuel tank with local fire prevention and environ- 2. Fuel filter ment protection regulations. 3. Fuel cock z Install fuel filter with all related parts in ENOM00098-A place, or fuel leak could occur, leading to Gear oil replacement catching fire or explosion. z Check fuel system regularly for leakage. ENOW00094-0 z Contact authorized dealer for fuel system WARNING services. Services by unqualified person could lead to engine damage. z Be sure that outboard motor is secured to transom or service stand, or accidental Fuel filters are provided inside the fuel drop or fall of outboard motor could lead tank and engine. to severe personal injury. z Be sure to lock outboard motor if it is

ENOM01405-0 tilted up, or accidental fall of outboard Fuel filter (for fuel tank) motor could lead to severe personal Water or dirt in the fuel tank will cause injury. 10 engine performance problems. z Do not go under outboard motor tilted up and locked, or accidental fall of outboard Check and clean the tank at specified motor could lead to severe personal times or after the outboard motor has injury. been stored for a long period of time (over three months). ENON00934-0 Note integral tank type Please dispose of used oil in a manner that 1. Drain all fuel from the fuel tank. is compatible with the environment. 2. Remove the fuel cock from the fuel We suggest you take it in a sealed con- tank and clean the fuel filter. Replace tainer to your local service station for rec- lamation. Do not throw it in the trash, pour it if necessary. it on the ground or down a drain.

1. Tilt down the outboard motor. 46 INSPECTION AND MAINTENANCE

2. Remove the oil plugs (lower and 4. Install the upper oil plug, and then upper), and completely drain the gear remove oil tube nozzle and install the oil into a pan. lower oil plug.

ENOW00095-0 CAUTION Do not reuse oil plug gasket. Always use new gasket and tighten oil plug properly to prevent entry of water into lower unit.

ENOF01617-0 3. Insert the oil tube nozzle into the lower oil plug hole, and fill with gear oil by squeezing the oil tube until oil flows out of the upper plug hole and bubbles is disappeared to remove the air. ENOF01619-0 ENON00033-0 Note ENOW00928-0 Use genuine gear oil or the recommended CAUTION one (API GL-5: SAE #80 to #90). Wipe off gear oil well immediately if spilled Required volume: and dispose of it in accordance with local approx. 180 mL (6.1 fl.oz) 3.5B2 approx. 90 ml (3.0 fi.oz.) 2.5A2/3.5A2 fire prevention and environment protection 10 regulations.

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

ENOF01618-0 INSPECTION AND MAINTENANCE 47

ENOM00232-C 2. Propeller Propeller replacement 3. Split pin ENOW00084-0 2. Remove the shear pin from the shaft. WARNING 3. Apply water proof grease to the propeller shaft before installing a new z Do not begin propeller removal and instal- propeller. lation procedure with spark plug caps attached, shift in forward or reverse, 4. Install the propeller with a new share main switch at other than “OFF”, engine pin. stop switch lock attached to the switch, 5. Install a new split pin into the propel- and starter key attached, or engine could ler's hole and bend it. accidentally start leading to serious personal injury. Disconnect battery cable if ENOM00087-C possible. Spark plugs replacement z The propeller edge is thin and sharp. Wear ENOW00087-0 the groves during replacement to protect your hands. WARNING

ENOW00208-A z Do not reuse spark plug with damaged insulation, or sparks can leak through CAUTION crack, potentially leading to electric shock, explosion and/or fire. z Do not reuse split pin. z Do not touch spark plugs immediately z After installing split pin, spread the pin after stopping engine as they will be hot apart to prevent it from falling out which and could cause severe burns if touched. could lead to the propeller coming off Allow motor to cool down first. during operation.

A worn-out or bent propeller will lower the motor's performance, and cause ENOW00929-0 engine trouble. CAUTION 1. Pull out the split pin from the propel- Use only the recommended spark plugs. ler boss and remove the propeller Spark plugs which have an different heat 10 from the shaft. range may cause engine damage.

If the spark plug(s) is fouled, has carbon build up, or is worn, it should be 1 replaced. When reusing spark plugs, remove dirt from the electrodes and adjust spark gap 2 to specification. 3 1. Stop the engine. 2. Remove the plug cap cover.

ENOF00242-0 3. Remove the spark plug caps.

1. Shear pin 48 INSPECTION AND MAINTENANCE

ENON00028-0 Note 1 z Spark plug torque: 27.0 Nm (20.0 ft-lb) [2.7 kgf-m] If a torque-wrench is not available when you are fitting a spark plug, a good esti- mate 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

ENOF02042-0 possible with a torque-wrench. 1. Socket wrench 4. Remove the spark plugs by turning it counter-clockwise, using a 13/16" (21 mm) 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 should be 0.9-1.0 mm (0.035-0.039 inches). If the gap is different, replace the spark plug with a new one Use spark plug (NGK BP6HS-10 or BPR6HS-10) or recommended ones.

1 2 ENOF00085-0

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

7. Install the spark plug by hand and turn it carefully to avoid cross-threading. 8. Tighten the spark plug to the specified torque. INSPECTION AND MAINTENANCE 49

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 original 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.

ENOF02043-0 50 INSPECTION AND MAINTENANCE

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

ENOF02044-0 INSPECTION AND MAINTENANCE 51

ENOM00100-A 3. Remove the spark plugs and put a 3. Off-season storage teaspoon of engine oil or spray storage oil into the combustion chamber ENOW00097-0 through the spark plug holes. WARNING 4. Pull the ricoil starter several times to lubricate inside the cylinder. Be sure to use cloth to remove fuel remain- ing in the cowl and dispose of it in accor- ENOW00930-0 dance with local fire prevention and WARNING environment protection regulations. z Be sure to remove stop switch lock to ENOW00096-A prevent ignited the spark plugs. z Put a cloth to spark plug hole and wipe up CAUTION any spilled engine oil, when cranking the Before servicing the motor for storage: outboard motor. z Remove the spark plug caps from the spark plugs. 5. Change the gear oil in the gear case z Do not run the motor out of the water. (See page 45). 6. Apply grease to grease point (See Before you put your outboard motor in page 50). storage, it is a good opportunity to have 7. Stand the outboard motor up verti- it serviced and prepared by your dealer. cally in a dry place. Be sure to use fuel stabilizer while running the motor before storage. (See page 52)

ENOM00101-F Engine 1. Wash the engine exterior and flush the cooling water system thoroughly with fresh water. Drain the water 10 completely. Wipe off any surface water with an oily rag. 2. Drain all fuel from the fuel system ENOF02036-0 (See page 52), and clean these parts. Keep in mind that if gasoline is kept in the carburetor for a long time, gum and varnish will develop, causing the float valve to stick, restricting the fuel flow. 52 INSPECTION AND MAINTENANCE

ENOW00066-1 2. Follow the instructions on the label CAUTION when adding the fuel stabilizer additive. Do not carry or store outboard motor in any of positions described below. 3. After adding the additive, let the out- Otherwise, engine's exterior parts may be board motor run in the water for 10 damaged or water may enter the cylinder minutes to make sure any old fuel in through the exhaust port and cause engine the fuel system has been completely problems. replaced by the fuel with additive. 4. Turn the engine OFF

ENON00891-0 Note If your motor is used occasionally, it is recommended to use a good fuel stabilizer in every tank of fuel and keep the container full to reduce condensation and evapora- tion. ENOF02035-0

ENON00021-D Note ENOM00970-C Fuel system draining If the outboard motor must be laid down, ENOW00028-A be sure drain the fuel completely in advance, then the port side face down on WARNING the cushion as shown in the drawing. For details on handling fuel, contact an authorized dealer.

Fuel and fuel vapors are extremely flammable and can be explosive. 10 z If fuel is spilled, wipe it up immediately. 1 z Keep the fuel tank well away from sources ENOF02037-0 of ignition, e.g. sparks or open flames 1. Handle z Perform all work outdoors or in a well ventilated place. ENOM00950-A Adding a fuel stabilizer ENOW00097-0 When adding a fuel stabilizer additive WARNING (commercially available), first fill the fuel tank with fresh oil and fuel. If the fuel Be sure to use cloth to remove fuel remain- tank is only partially filled, air in the tank ing in the cowl and dispose of it in accordance with local fire prevention and can cause the fuel to deteriorate during environment protection regulations. storage. 1. Before adding fuel stabilizer additive, drain the carburetor (See page 52). INSPECTION AND MAINTENANCE 53

1. Close the fuel cock. 7. Check the drained fuel for the presence of water or other contaminants. If either is present, reassemble the outboard motor, refill the carburetor with fuel, and then drain the fuel again. Repeat this procedure until no water or other contaminants are present in the drained fuel.

1 ENOM00104-G 4. Pre-season check ENOF02045-0 1. Fuel cock The following steps must be taken when 2. Turn the outboard motor. first using the engine after off season 3. Place an approved fuel container storage. under the drain screw. 1. Check that the shift and throttle 4. Loosen the carburetor drain screw. function properly. (Be sure to turn the propeller shaft when checking the shift function or else the shift linkage may be damaged.) 2. Fill fuel tank with oil and fuel. 3. Open the fuel cock. 4. Start the engine and warm up the engine for 3 minutes in the “NEU- TRAL” position. 1 5. Run the engine for 5 minutes at the ENOF02046-0 slowest speed. 1. Carburetor drain screw 6. Run the engine for 10 minutes at half 10 throttle. The oil used for storage 5. Leave the outboard motor in this inside the engine will be circulated position until all fuel has been out to assure optimum performance. drained. 6. When thoroughly drained, retighten the drain screw securely. 54 INSPECTION AND MAINTENANCE

ENOM00105-D ENOM00107-A 5. Submerged outboard motor 7. Striking underwater object

ENOW00098-0 ENOW00935-0 CAUTION CAUTION Do not attempt to start submerged outboard Striking the sea bottom or an underwater motor immediately after it is recovered, or object may severely damage the outboard engine could be severely damaged. motor.

After taking your outboard motor out of Follow the procedure below and consult the water, immediately take it to your a dealer as soon as possible. dealer. 1. Stop the engine immediately. The following are the emergency mea- 2. Check the control system, gear case, sures to be taken for a submerged out- boat transom etc. board motor, if you can not take it your 3. Return to the nearest habor slowly dealer right away. and carefully. 1. Wash the outboard motor with fresh 4. Consult a dealer check the outboard water to remove salt or dirt. motor before operation again. 2. Remove the spark plugs, and completely drain the water from the engine by pulling recoil starter several times. 3. Inject a sufficient amount of engine oil through the spark plug holes. Pull the recoil starter rope several times to circulate the oil throughout

the outboard motor. ENOF01145-0 10 ENOM00106-A

6. Cold weather precautions ENOM00120-0 8. Auxiliary outboard motor If you moor your boat in cold weather at operation temperatures below 0°C (32°F), there is the danger of remained water freezing in When the auxiliary outboard motor will the cooling water pump, which may dam- not be used, be sure to remove the stop age the pump, impeller, etc. To avoid this switch lock, shift into forward, and then problem, submerge the lower half of the tilt the outboard motor up. Otherwise, outboard motor into the water. over-rotation of the propeller due to water spray could damage the gear. 55 TROUBLESHOOTING

ENOM01307-0 If you encounter a problem, consult the check list below to determine the cause and to take the proper action. An authorized dealer will always be happy to provide any assistance and information.

Possible cause Engine failing to start failing Engine starting soon Engine but stopping idling Poor speedhigh Engine abnormally speed low Engine abnormally engine speedsHigh not possible engine of Overheating zz Empty fuel tank zz Incorrect connection of fuel system zzz zzzAir entering fuel line zzz zzzDeformed or damaged fuel pipe zzz zzzClosed air vent on fuel tank zzz zzzClogged fuel filter, fuel pump, or carburetor z zzzUse of improper engine oil

FUEL SYSTEM FUEL z z zzzUse of improper gasoline zzzExcessive oil in mixture z Shortage of oil in mixture z Exessive supply of fuel zzz zzzPoor carburetor adjustment zz zzzSpark plug other than specified zzz zz Dirt, soot, etc. on spark plugs zzz zz No spark or weak spark z Short circuit of engine stop switch 11 zzzzIgnition timing incorrect

ELECTRICAL SYSTEM z Lock plate not fitted to stop switch z Sheard shearpin zzzInsufficient cooling water flow, clogged or defective pump zzzCavitation or ventilation zzzzIncorrect propeller selection zzzzzDamaged and bent propeller OTHERS zzzImproper thrust rod position zzzzUnbalanced load on boat zzzzTransom too high or too low 56 TOOL KIT AND SPARE PARTS

ENOM01308-0 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 × 13 mm Service tools Socket wrench 1 21 mm Socket wrench handle 1 Screwdriver (Phillips-type 1Adapter-type and flat head) Emergency starter rope 1 ø4–1000 mm Spare stop switch lock 1 Spare parts Spark plug 1 NGK: BPR6HS-10 Share pin 1 Split pin 1

* Not included as standard accessories in some markets.

12 58 PROPELLER TABLE

ENOM01309-0 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 rpm measured at wide open throttle while cruising is within the recommended range.

2.5A2: 3800–5200 min-1 (rpm) 3.5A2/3.5B2: 4200–5300 min-1 (rpm)

ENON00245-0 Note

Each size shows number of propeller blades × diameters × pitch.

Propeller Size Propeller Mark Material Diameter × pitch Light boats 3 × 188 × 178 mm 7 Plastic 3 × 7.4 × 7.0 in

3 × 188 × 145 mm Plastic 6 3 × 7.4 × 5.7 in Aluminum 3 × 188 × 110 mm 4.5 Plastic Heavy boats 3 × 7.4 × 4.3 in

13 OWNER’S MANUAL

M 2.5A2 M 3.5A2 M 3.5B2

5-4, Azusawa 3-Chome, Itabashi-Ku Tokyo 174-0051, Japan Tel: +81-3-3966-3117 Fax: +81-3-3966-0090 www.tohatsu.com