Tanaka 945601 - TOB 120 User manual

Owners Manual
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7114193

A Message to Tanaka Customers ...
Welcome to the world of Tanaka equipment, We If service is required, be prepared to supply the
are pleased that you have purchased the best service person with the Model and Serial Number
equipment available. The care you give :your of the equipment, as wel! as a full description of
Tanaka equipment will determine the satisfactions, theproblem encountered,
and service life you will obtain from it. Uselth!s .........,__/
manual as your guide. By observing the
instructions and suggestions in this manual,:your =, NOTE:iTiie_descriptions and speCificationS con-
Tanaka equipment will serve you well for many rained in this manual were in effect at the time the
years, manual was, approved for printing. Tanaka
Your Tanaka dealer will be happy to supply any
service or advice which may be requiredto keep
your Tanaka equipment operating,at peak
efficiency, He stocks genuine Tanaka parts and
lubricants; manufactured with the same precision
and skill as the original equipment, His factory
trained staff is kept well informed on the best
methods of servicing Tanaka equipment and is
ready and able to serve you.
company reserves the right to discontinue models
without notice and without incurring obligation, The
equipment described within this manual may not
be identified as either standard or optional and the
various illustrations may not all be applicable to
your particular unit. If you have questions, always
check with your Tanaka dealer.
Safety Alert Symbol And Notations
The following safety notations are used throughout
this manual to call attention to special information
or operating procedures, Understand the message
in each notation and be alert to unsafe conditions
and the possibility of personal injury.
NOTE" ANOTE points out general reference
information regarding proper operation and
maintenance practices,
IMPORTANT; An IMPORTANT statement indicates
specific procedures or information that is required
to prevent damage to the machine or its
attachments.
=iIii = This safety alert symb01:ls used to _ _
attract your attentionl_:PERSONAL
SAFETY IS INVOLVEDI When you see
this symbol -BECOME ALERT -HEED
ITS MESSAGE.
IHI, I.II I
CAUTION: ACAUTION identifies safe
operating practices or indicates unsafe
conditions that could result in personal
Injury.
WARNING: A WARNING describes a
condition where failure to follow the
Instructions could result in severe
personal Injury.
DANGER: A DANGER designates a
condition where failure to follow In-
structions or heed warning will most
likely result in serious personal Injury
or death.
:!

Contents
i:
Safety Precautions .................. 1
Dealer .Preparation for Operation ....... 4
Controls and Features ................ 5
Operation ......................... 6
Operating Tips ..................... 11
Lubrication and Maintenance .......... 11
Adjustments ....................... 14
Storage ............................ 15
Specifications ...................... 16
Warranty ............. Inside Back Cover
Models
Model 945601 -TO8 120
Outboard Motor
Serial No. 000101 and up
Model 945603 -TOB 300
Outboard Motor
Serial No. 000101 and up
Instructions contained in this manual apply to
models listed on this page. Use the instructions
that apply to your unit.
Specific Model Number and Serial Number of your
equipment are on alabel on the unit. Record num-
bers below and use them whenever parts or
service are required.
Model Number-
Serial Number-
Engine Serial Number -
Safety Precautions
Training
Read and understand this Owner's Manual before
operating this unit. Be thoroughly familiar with
controls and proper use of equipment. Know how
to stop unit quickly inan emergency.
This Outboard Motor is a quality marine product
designed to give years of dependable service
when operated and maintained properly, if rotating
propeller comes in contact with your body, it will
cause severe personnel injury. If blade comes in
contact with submerged hard objects, it may
damage blade. Be aware of sudden lifting of motor
leg and propeller out of the water which may occur
if an underwater object is struck.
Understand and follow each Danger, Warning,
Caution and instruct on decals installed 0n
equipment or described in this manual.
Use only replacement parts designed for this unit.
See your Tanaka Dealer for a complete list.
Although some unauthorized parts may appear to
be adaptable, their use may be extremely
dangerous and could cause serious personal
injury. This is especially true of propellers which
may be of poor construction or improperly
balanced.
NEVER allow children to operate or play with unit.
DO NOT allow adults to operate unit without proper
instructions. Anyone using this unit must
understand the information in this manual.
Safe operation of this equipment requires complete
and unimpaired attention at all times. DO NOT
operate unit iffatigued, during or after consumption
of medication; drugs or alcohol.
When transporting unit in a vehicle, secure it to
prevent it from sliding or tipping over which could
cause damage to your unit or spill fuel.
PadNumber045606
© Tanaka 1

Safety Precautions (Cont.)
Preparation
Thoroughly inspect Outboard Motor for damage,
chipped propellers, fuel leaks, etc. before operating
this unit.
NEVER attempt to make any adjustments to unit
while motor is running (except where specifically
recommended).
Gasoline is highly flammable and its vapors are
explosive. Handle with care. Use an approved
(RED) gasoline container.
NEVER allow smoking materials, sparks or flame
(match, pilot lightl etc.) near unit or gasoline
container.
Check fuel supply before starting motor. Always
start boating trips with a full tank.
DO NOT fill fuel tank indoors, when motor is
running or while motor is still hot. Wipe off any
spilled gasoline, allow vapors to dissipate and
move fuel container 10 feet (3m) away from unit
before starting motor.
Operation
Keep equipment in good condition. Keep all guards
and shields in place and safety devices operating
properly. Be sure that Throttle Lever stops motor
when moved to stop position and Lever moves
freely. On units equipped with Stop button, be sure
button stops unit.
Exhaust fumes contain carbon monoxide, an
odorless and deadly gas. DO NOT run motor in
enclosed or poorly ventilated areas.
Before starting, make sure unit is properly secured
to boat transom using clamp stud handles. Be sure
a safety chain, from unit to boat, is installed. Check
clamp handles for tightness periodically.
Always carry a spare propeller_ shear pins, hair
pins, spark plug and necessary repair tOOlS such
as pliers, screwdriver, and wrenches.
When starting unit, be s
objects because when motor is started, throttle
may be set high enough to rotate the propeller.
After motor is started and idling smoothly, propeller
must not rotate. DO NOT operate unit if propeller
rotates when motor is idling.
DO NOT put hands or other body parts near
rotating parts.
Maintain a firm hold on twist grip at all times to
help keep control of the unit.
Operate equipment only when there is good
visibility and light.
Never allow swimmers or waders near unit while it
is in operation. The operator is responsible for the
safety of swimmers and boaters in the area.
After mounting motor on transom, set proper motor
trim according to size and weight of the boat. See
Tilt Adjustment in Operation section of this manual.
Move Throttle Lever to stop position to stop
propeller. Always keep a fire extinguisher in the
boat along with life vests and other U.'S. Coast
Guard approved safety equipment.
Before attempting to make any adjustment, repairs,
inspections or cleaning unit, stop motor, wait for
moving parts to stop, allow unit to cool then
remove wire from spark plug.
If equipment vibrates abnormally during operation,
stop motor at once, wait for rnoving parts to stop,
and remove wire from spark plug. Abnormal
vibration is a warning of trouble. Repair any
damage before restarting unit. (See your Tanaka
Dealer.)
After striking a submerged object, stop motor, wait
for moving parts to stop, then remove wire from
spark plug. Thoroughly inspect unit for any
damage. Repair damage before restarting and
operating unit ..... '
2

Safety Precautions (Cont.)
Before shutting motor off, after operating under full
load for an extended period, lower motor speed
and allow it to idle for a few minutes so that motor
parts can cool evenly.
tn the event of an emergency, stop the motor by
moving Choke Lever to ful! choke position.
Boating, Trailering and Auxiliary Use
Tips:
When trailering this unit, secure motor !nan upright
(vertical) position againstboat transom. Do not
trailer with unit tilted up. If unit must be transported
while tilted up, place a suitable brace, such as a 2
x 4, between motor bracket and motor leg. Tie
down motor leg against brace to prevent damage
to motor leg.
When transporting unit in a vehicle, secure it to
prevent turnover which could result in spilled fuel
or damage to unit. ......
To prevent fuel leakage from the carburetor when
unit is tilted, close vent screw on fuel tank, turn off
fuel shutoff valve, and allow unit to runat idle until
it stops.
When loading or launching a boat on a trailer, tilt
motor up to prevent propeller from striking ramp or
underwater objects.
An auxiliary adjustable position motor bracket is
recommended when using unit as auxiliary power
for watercraft.
Maintenance and Storage
Periodically check that Throttle Lever stops motor
when moved to stop position and Lever moves
freely.
Periodically check operation ofpropeller clutch-
brake. Propeller should stop almost immediately
when throttle is fully released. DO NOT operate
unit if brake does not operate properly. Have unit
serviced by your Tanaka dealer before operating.
Discard propellers that are broken or damaged in
any way. Replace only with Tanaka original
equipment replacement parts for safety.
Keep all nuts, bolts and screws tight and be sure
equipment is in safe working condition. Check all
hardware at regular intervals.
Take all possible precautions when leaving unit
unattended. Remove and keep wire away from
spark plug to prevent accidental starting or
unauthorized use.
L_'
When loading boatl distribute weight evenly to
prevent tipping. Keep heavy loads low in the boat.
Do not stand up in a small'boat.Standing, bow
riding, seat back and gunwale riding can be
dangerous.
NEVER store unit with gasoline in tank inside a
building where fumes may reach an open flame or
spark. Allow motor to cool before storing in any
enclosure.
3

Dealer Preparation for Operation
Customer Note: Your Tanaka Dealer is expected
to complete these preparation steps and review
important information, including this manual, with
you before or upon delivery of this unit.
Preparation information is included here so that
you and your dealer may review it together.
WARNING: Failure to follow all
Instructions could result in personae
Injury and/or damage to unit. Remove
wlre from spark plug before attempting
any adjustment or assembly
procedures.
Instructions contained in this manual apply to
several models. Use the instructions that apply to
your unit.
Fuel Mixture
1
4
1. Steering Handle
2. Joint Pipe Holder
3. Handle Stopper
4. Wing Head Bolt
IMPORTANT: 2 cycle engines require that oil be
mixed with fuel. Refer to Fuel in Operation section
of this manual for recommended mixture.
Figure 1: Handle Installation -Model 120
Handle Assembly
Model 120
Place handle (throttle lever up) into position on
joint pipe holder with notch on end of handle
against handle stopper. Secure to joint pipe holder
with wing head bolt; Iockwasher, two plain
washers, and Hair Pin. Attach throttle cable to
carburetor bracket.
Model 300
Place handle (throttle cable down) into position on
clutch case. Be sure flat of handle is set in notch
of handle stopper. Secure to clutch case with 8 x
30 bolt, Iockwasher, and two plain washers. Attach
throttle cable to carburetor. 1. Steering Handle
2. Handle Stopper
Figure 2: Handle Installation Model 300

Gear Housing
Dealer Preparation (Cont.)
Delivery
Check gear housing for proper level of grease prior
to operation. See Lubrication and Maintenance
section for proper procedures.
Registration
Complete Outboard Motor Warranty Registration
Form and mail original copy to Tanaka.
Warranty is registered under model and serial
number found on label attached to unit.
Using this Owner's Manual instruct customer on
controls and operation of unit. Demonstrate how to
start and stop the engine. Emphasize safety and
discuss Safety Precautions.
Explain recommended fuel and oil mixture,
lubrication and maintenance of unit.
Advise customer on adjustments and propeller
shear pin replacement.
Give customer his Owner's Manual and advise him
to thoroughly read and understand it.
2O
Controls and Features
1
2
13
12
10 9
1. Fuel Filler Cap and
•Air Vent Screw
2. Starter Handle
3. Throttle Control Lever
4. Steering Handle
5. Transom Bracket
:6. ClarnpStud Handles
7. Drive Shaft Pipe
8. Cavitation Plate
9. Gear Housing
10. GearHouslng Cover
11. Propeller
12. Fill and Dratn Plug
13. Cotter Pin
Figure 3: Controls and Features -Model t20
14. Exhaust Outlet
15. Muffler Pipe
16. Tilt Pin Adjustment
17. FuelShut-0ffValve
18. Choke Lever
19. Spark Plug
20. Power Head
5

Controls and Features (Cont.)
1. Starter Handle
2. Choke Lever
3. Power Head
4. Spark Plug
5. Twist Grip
6. Steering Handle
7. Clamp Stud Handles
8. Transom Bracket
9. Drive Shaft Pipe
10. Cavitation Plate
11. Fill and Draln Plug
12. Gear Housing
13. Gear Housing Cover
14. Cotter Pin
15. Propeller
16. Exhaust Outlet
17. Muffler Pipe
18. Tilt Pin Adjustment
Figure 4: Controls and Features - Model 300
19. Reverse Driving Lock
20. Dual Automatic
Clutch Housing
21. Fuel Sediment Bowl
and Filter
22. Fuel Shut Off Valve
23. Stop Button
24. Fuel Filler Cap and
Air Vent Screw
Operation
PRE-STARTING
IMPORTANT: 2 cycle engines require that oil be
mixed with gasoline (refer to Fuel section below for
proper mixture).
Check air cleaner element for dirt. Clean as
required. (Refer to Lubrication and Maintenance
section of this manual.)
CAUTION: Make sure all hardware Is
tight, all safety devices are In place and
operating, all adjustments are made
correctly, that Stop Switchon models
equipped with them,, stops motor and
that Throttle Lever moves freely.

Operation(Cont.)
Fuel
IMPORTANT: Failure to mix oil with gasoline wild
result in seizure and severe damage to motor. DO
NOT use gasohol or gasoline containing alcohol
because alcohol will attack and cause internal
parts to deteriorate. Use unleaded gasoline for best
performance.
NOTE: To prevent foreign particles from entering
tank while filling: wipe dust, dirt and debris from
around cap before r_emoving it.
During operation, occasionally check clamps for
tightness. Loose clamps may result in damage to
motor or boat.
1
illu ill lu
WARNING: Gasoline is highly flam-
mable and must be handled with care.
Allow motor to cool several minutes
before removing fuel tank cap. Never fill
tank when motor is running or hot from
operation. Do not allow open flame,
matches, or smoking In area. DO NOT
overfill. Wipe up any spills and allow
vapors to dissipate. Use approved
(Red) gasoline container.
\
1. Transom Bracket 2. Clamp Stud Handles
Tanaka 2 cycle oil has been formulated to insure
maximum motor performance and increased motor
life. Premix Tanaka oil per instructions on
container. If Tanaka oil is not available, select a
quality 2 cycle BIATC (Boating Industry Association
Two Cycle) approved oil and use unleaded
gasoline, u$_ /) s_: I oil
tf oil manufacturer does not recommend a specific
mixing ratio, mix at a 1 to 25 ratio (5-1/2 ounces oil
per gallon of unleaded gasoline).
NOTE: After fuel mixture has been left standidg for
a prolonged period of time it will begin to separate,
therefore thoroughly shake mixture before using,
Mounting To Boat
Figure 5: Mounting to Transom
Tilt Adjustment
Motor tilt must be adjusted to propel boat through
the water with an even keel. if the motor is tilted
too far outward, bow of the boat would ride too
high in the water obscuring the operator's view and
be susceptible to sudden movement by high winds
and waves. If the motor is tilted too far inward, the
bow may dig into high waves or wakes.
A 12 to 15 degree tilt is recommended. This angle
may need to be adjusted according to the weight
of boat and passengers.
improper transom height or tilt angle may result in
boat "porpoising" or motor cavitation.
Motor must be mounted in center of boat transom. •
Recommended transom height is 20". Clamp to Boat porpoising is a condition where the bow of the
transom with clamp stud handles turned hand tight, boat raises and falls rapidly and continuously.
Secure unit to transom using a safety chain (not
supplied). _
,7

Operation (Cont.)
.... WRONG __BOW UP
Figure 6: Tilt Adjustment & Transom
Mounting
Motor cavitation is a condition where turbulent air
passes by the propeller resulting in an increase in
motor speed coupled with a rapid drop in boat
speed. These conditions can also be caused by
fast turns, rough water, wrong or obstructed
propeller, or poor boat design.
To adjust; stop motor and allow propeller to come
to a full stop. Tilt motor all the way up to the
storage position, then remove Tilt Lock Bracket
Pin. Re-position lock pin in one of five angle
adjustment holes in clamp bracket. Secure Tilt
Lock Pin with Hair Pin.
To determine the best motor tilt angle, start with
the Titt Lock Adjustment Pin in the center set of
holes. In calm water, operate boat at full throttle
with a normal load. Adjust tilt angle as necessary
to establish a near even keel.
Steering Adjustment
The amount of resistance to movement of the
steering handle is adjustable. Loosen or tighten the
steering tension bolt using an open end spanner
wrench (supplied).
IMPORTANT; The tension bolt may fall out if
loosened too much.
1. Steering Tension Bolt
2. Tilt Lock Bracket Pin & Hair Pin
Figure 7: Steering Tension Adjustment
STARTING
CAUTION: DO NOT attempt to start
motor at this time. Familiarize yourself "
with controls to see what they do, how
they work and thoroughly read and
understand entire Owner's manual first.
WARNING: Insure all guards and safety
devices are Installed and working
properly before starting.
WARNING: Rotating propeller can
cause serious Injury. Be sure propeller
is clear of swimmers, waders, or
underwater objects because when
Throttle is set at starting position motor
speed will be fast enough for clutch to
engage and propeller to rotate.
8