TOHATSU M 115A2 Owner's manual

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MANUAL

OWNER’S

OB No.003-11039-BAF1

M 60C

M 70C

M 70CX

M 90A

2

M 115A

2

M 140A

2

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.

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 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 (indicated both on

the bottom cowl and on the cylinder block). The serial number will be needed when order-

ing parts, and when making technical or warranty inquiries.

Serial Number:

Serial Number: Date of purchase:

ENOF02301-0

90

ENOF02302-0

115/140

ENOF02300-0

60/70

ENOF02371-0

ENOF02373-0

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

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

age.

ENOW00002-0

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

ENOW00003-0

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.

DANGER

WARNING

CAUTION

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

7. Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

8. Trim angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

9. Tilt up and down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

10.Shallow water operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

8. REMOVING AND CARRYING THE OUTBOARD MOTOR. . . . . . . . . . . . . . 62

1. Removing the outboard motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

2. Carrying the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

3. Traillering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

9. ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

1. Throttle grip friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

2. Remote control lever friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

3. Trim tab adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

10. INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

1. Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

2. Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

3. Off-season storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

4. Pre-season check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

5. Submerged outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

CONTENTS

6. Cold weather precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

7. Striking underwater object. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

8. Operation with multiple outboard motors . . . . . . . . . . . . . . . . . . . . . . . . . 87

11. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

12. TOOL KIT AND SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

13. PROPELLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

9

1 GENERAL SAFETY INFORMATION

2. SPECIFICATIONS

3. PARTS NAME

4. LABEL LOCATIONS

5. INSTALLATION

6. PRE-OPERATING PREPARATIONS

7. ENGINE OPERATION

8. REMOVING AND CARRYING THE

OUTBOARD MOTOR

9. ADJUSTMENT

10.INSPECTION AND MAINTENANCE

11.TROUBLESHOOTING

12.TOOL KIT AND SPARE PARTS

13.PROPELLER TABLE

INDEX

2

14

3

4

5

6

7

8

9

10

11

12

13

14

1

10

1

GENERAL SAFETY INFORMATION

ENOM00009-0

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

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

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 Floatation Device) while on the boat.

WARNING

GENERAL SAFETY INFORMATION 11

1

ENOM00010-0

SERVICING, REPLACEMENT PARTS & LUBRICANTS

We recommend that only an authorized service shop perform service or maintenance on

this outboard motor. Be sure to use genuine parts, genuine lubricants, or recommended

lubricants.

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 67). 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

2

SPECIFICATIONS

ENOM00810-A

MODEL FEATURE

(z) These models can be purchased with remote rigging kit or multi function tiller handle.

ENOM00811-B

MODEL NAME EXAMPLE

M140A2 EPTOL

Model M60C M70C M70CX

Type EPTO MFG EPTO MFG

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

Mnual tilt

Model M90A2 M115A2 M140A2

Type EPTO EPTO EPTO

Transom heights

S

L z z z

UL z z z

Tiller handle

Remote control z z z

Power tilt z z z

Gas-assisted tilt

Mnual tilt

M 140 A 2 E P T O L

Model

descrip-

tion

Horse

power

Product

generation

Miner

change

Starter

system

Steering

system

Tilt

system

Lubrication

system

Shaft length

M (X) = Two

stroke

F= Four stroke

D= Two stroke

DI

-

A and up

2 and

up

E=

Electrical

start

M=

Manual

start

P=Remote

controlࠉ

(Pleasure)

F=Tiller handle

(Fisher)

T= Power

trim&tilt

G=

Gas assist

Blank=

Manual tilt

O=

Oil auto-mxing

Blank=

Oil Pre-mixing

S= Short 15 in

L= Long 20 in

UL=

Ultra long 25 in

SPECIFICATIONS 13

2

ENOM01721-0

Remark: Specifications subject to change without notice.

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

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

Item MODEL

60C/70C

EPTO

70C/70CX

MFG

Overall Length mm (in) Approx. 720 (28.3) Approx. 1280 (50.4)

Overall Width mm (in) Approx. 360(14.2)

Overall Height

L mm (in)

1415 (55.7) 1455 (57.3)

UL mm (in)

1542 (60.7) 1582 (62.3)

Transom Height

L mm (in)

517 (20.4)

UL mm (in)

644 (25.4)

Weight

L kg (lb) 115 (254) 105.5 (233)

UL kg (lb)

117.5 (259) 108 (238)

Output kW (Hp) 60C: 44 (60) / 70C/70CX: 52 (70)

Max. Operating Range rpm 5150-5850

Idle Speed in Neutral Gear

rpm 900

Trolling Speed in Forward Gear

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 mL (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

25

Fuel

Unleaded regular gasoline pump posted 87 Octane (research octane rating of 91)

Fuel Tank Capacity L (US gal) 25 (6.6)

Engine Oil Genuine motor oil or recommended one (TCW-III)

Fuel : Engine oil Mxing Retio

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)

SPECIFICATIONS14

2

ENOM01722-0

Remark: Specifications subject to change without notice.

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

90A2, 115A2/140A2 EPTO

Item MODEL 90A2 EPTO 115A2 EPTO 140A EPTO

Overall Length mm (in) Approx. 690 (27.2) Approx. 747 (29.4)

Overall Width mm (in) Approx. 360 (14.2) Approx. 390 (15.4)

Overall Height

L mm (in) 1435 (56.5) 1560 (61.4)

UL mm (in) 1562 (61.5) 1687 (66.4)

Transom Height

L mm (in) 517 (20.4)

UL mm (in)

644 (25.4

Weight

L kg (lb) 135 (298) 164 (362)

UL kg (lb) 137.5 (303) 166.5 (367)

Output kW (Hp) 66 (90)

85 (115) 103 (140)

Max. Operating Range rpm 5150-5500

5200-5700

Idle Speed in Neutral Gear

rpm 900

Trolling Speed in Forward Gear

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)

Piston Displacement mL (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 pump posted 87 Octane (research octane rating of 91)

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 1.85 (13 : 24)

15

3

PARTS NAME

ENOM01700-0

70 MFG

1

2

3

8

9

5

6

7

3

14

12

10

11

15

13

17

18

19

4

16

ENOF02303-0

1

Tilt Handle

2

Top Cow l

3

Hook Lever

4

Water Check Port

5

Reverse Lock Lever

6

Anti-ventilation Plate

7

Trim Tab

8

Propeller

9

Water Inlet

10

Clamp Bracket

11

Thrust Rod

12

Anode

13

Throttle Grip

14

Shift Lever

15

Stop Switch

16

Starter Handle

17

Gas Asistant

18

Spark Plug

19

Fuel filter

PARTS NAME16

3

ENOM01701-0

60/70 EPTO

1

2

3

8

9

5

4

6

7

11

10

14

15

13

16

12

17

18

19

20

21

3

ENOF02304-0

1

Tilt Handle

2

Top Cow l

3

Hook Lever

4

Water Check Port

5

PTT Switch

6

Anti-ventilation Plate

7

Trim Tab

8

Propeller

9

Water Inlet

10

Clamp Bracket

11

Thrust Rod

12

Power Trim & Tilt

13

Anode

14

Fuel Connector

15

Battery Cords

16

Filler Lid

17

Oil Tank

18

Fuel Filter

19

Oil Filter

20

Spark Plug

21

Tilt Stopper

PARTS NAME 17

3

ENOM01702-0

90, 115/140 EPTO

2

3

4

7

8

5

6

10

9

2

12

13

11

17

14

15

16

18

1

ENOF02305-0

1

Top Cow l

2

Hook Lever

3

Water Check Port

4

Gear Case

5

Anti-ventilation Plate

6

Trim Tab

7

Propeller

8

Water Inlet

9

Clamp Bracket

10

Manual Valve (Port side)

11

Power Trim & Tilt

12

Battery Cords

13

Filler Lid

14

Oil Tank

15

Fuel Filter

16

Oil Filter

17

Spark Plug

18

Tilt Stopper

PARTS NAME18

3

1

2

4

5

6

7

8

10

9

14

13

12

11

ENOF00127-E

ENOM00822-0

Remote control box & Fuel tank

1

Control Lever

2

Neutral Lock Arm

3

PTT Switch

4

Free Throttle lLver

5

Main Switch

6

Stop Switch

7

Stop Switch Lock

8

Stop Switch Lanyard

9

Fuel Gauge

10

Air Vent Screw

11

Fuel Tank Cap

12

Fuel Connector (Engine Side)

13

Primer Bulb

14

Fuel Connector (Fuel Tank Side)

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