TOHATSU BFT 75A User manual

OWNER’S MANUAL
O W N E R’S
OM_BFT75-100A_US_Cover.indd 1
uK-ihsabatI,emohC-3awasuzA,4-5
Tokyo 174-0051,Japan
Tel:[phone] Fax:[phone]
www.tohatsu.com PRINTED IN JAPAN
XXX.XXXX.XX
31ZZ0T03
00X31-ZZ0-T030
OWN ER’S MANUAL
BFT 75A
BFT 90A BFT 75A
BFT 90A

Keep this Owner’s Manual handy, so you can refer to it at any time. This Owner’s
Manual is considered a permanent part of the outboard motor and should remain with
the outboard motor if resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Honda Motor Co., Ltd. reserves the right, however, to discontinue or change
specifications or design at any time without notice and without incurring any obligation whatever. No part of this publication may be reproduced without written permission.
The engine exhaust from this
product contains chemicals
known to the State of California to
cause cancer, birth defects or
other reproductive harm.

1
INTRODUCTION
Congratulations on your selection of
a TOHATSU outboard motor. We are
certain you will be pleased with your
purchase of one of the finest
outboard motors on the market.
We want to help you get the best
results from your new outboard
motor and to operate it safely. This
manual contains information on how
to do that; please read it carefully.
As you read this manual you will
find information preceded by a
symbol. That information
is intended to help you avoid damage
to your outboard motor, other
property, or the environment.
We suggest you read the warranty
policy to fully understand its
coverage and your responsibilities of
ownership.
When your outboard motor needs
scheduled maintenance, keep in mind
that your TOHATSU dealer is
specially trained in servicing
TOHATSU outboard motors. Your
TOHATSU dealer is dedicated to
your satisfaction and will be pleased
to answer your questions and
concerns.
Best Wishes,
Tohatsu Corporation

2
INTRODUCTION
A FEW WORDS ABOUT
SAFETY
Your safety and the safety of others
are very important. And using this
outboard motor safely is an important
responsibility.
To help you make informed
decisions about safety, we have
provided operating procedures and
other information on labels and in
this manual. This information alerts
you to potential hazards that could
hurt you or others.
Of course, it is not practical or
possible to warn you about all the
hazards associated with operating or
maintaining an outboard motor. You
must use your own good judgment.
You will find important safety information in a variety of forms, including:
•Safety Labels — on the outboard motor.
•Safety Messages — preceded by a safety alert symbol and one of
three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
•Safety Headings — such as IMPORTANT SAFETY INFORMATION.
•Safety Section — such as OUTBOARD MOTOR SAFETY.
•Instructions — how to use this outboard motor correctly and safely.
This entire book is filled with important safety information — please read it
carefully.
You WILL be KILLED or SERIOUSLY
HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY
HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow
instructions.

3
CONTENTS
OUTBOARD MOTOR SAFETY .................................... 7
IMPORTANT SAFETY INFORMATION................. 7
SAFETY LABEL LOCATION................................... 9
CONTROLS AND FEATURES .................................... 11
CONTROL AND FEATURE IDENTIFICATION
CODES................................................................... 11
COMPONENT AND CONTROL LOCATIONS..... 12
CONTROLS.............................................................. 20
Remote Control Box: ............................................. 20
Side-Mount Type ................................................. 20
Ignition Switch................................................ 20
Emergency Stop Switch Clip and Emergency
Stop Switch .................................................. 20
Gearshift/Throttle Control Lever .................... 21
Fast Idle Lever ................................................ 22
Panel-Mount Type................................................ 23
Ignition Switch................................................ 23
Emergency Stop Switch Clip and Emergency
Stop Switch .................................................. 24
Gearshift/Throttle Control Lever .................... 25
Fast Idle Button............................................... 26
Top-Mount Type .................................................. 27
Ignition Switch................................................ 27
Emergency Stop Switch Clip and Emergency
Stop Switch .................................................. 27
Gearshift/Throttle Control Lever .................... 28
Fast Idle Button ...............................................30
Tiller-Handle (optional equipment):.......................31
Ignition Switch ................................................31
Emergency Stop Switch Clip and Emergency
Stop Switch...................................................31
Throttle Grip....................................................32
Throttle Friction Adjuster................................33
Gearshift Lever................................................34
Steering Friction Adjusting Knob ...................35
TRL (Trolling) Control Switch
(optional equipment) .........................................36
Power Trim/Tilt Switch ........................................37
Power Tilt Switch .................................................38
Manual Relief Valve.............................................38
Tilt Lock Lever.....................................................39
Engine Cover Latch (front/rear) ...........................39
Trim Tab ...............................................................39
INSTRUMENTS .......................................................40
Trim Meter (optional equipment) .........................40
Tachometer (optional equipment) ........................40
Fuel Gauge (optional equipment) .........................40

4
CONTENTS
INDICATORS........................................................... 41
Alternator (ACG) Indicator.................................. 41
Malfunction Indicator........................................... 42
Oil Pressure Indicator........................................... 42
Overheat Indicator................................................ 43
Cooling System Indicator..................................... 44
OTHER FEATURES ................................................ 44
Water Separator Buzzer ....................................... 44
Overrev Limiter.................................................... 45
Portable Fuel Tank (optional equipment) ............ 45
Fuel Filler Cap Vent Knob................................... 45
Fuel Priming Bulb ................................................ 46
Anodes.................................................................. 46
NMEA Interface Coupler..................................... 47
Operating Hour Notification System ................... 47
BEFORE OPERATION ................................................. 51
ARE YOU READY TO GET UNDERWAY? ......... 51
IS YOUR OUTBOARD MOTOR
READY TO GO? ................................................... 51
Tiller Handle Height/Angle Adjustment
(optional equipment) ......................................... 53
OPERATION ................................................................. 55
SAFE OPERATING PRECAUTIONS ..................... 55
BREAK-IN PROCEDURE........................................55
PORTABLE FUEL TANK (optional equipment).....56
FUEL HOSE CONNECTIONS.................................57
FUEL PRIMING........................................................58
INFREQUENT OR OCCASIONAL USE ................59
STARTING THE ENGINE .......................................59
Remote Control Box:............................................59
Side-Mount Type...............................................59
Panel-Mount Type .............................................62
Top-Mount Type ...............................................65
Tiller-Handle: .......................................................67
EMERGENCY STARTING......................................70
STOPPING THE ENGINE........................................72
Emergency Engine Stopping ................................72
Normal Engine Stopping ......................................73
GEARSHIFT AND THROTTLE OPERATION ......77
STEERING ................................................................80
CRUISING.................................................................81
SHALLOW WATER OPERATION.........................84
MOORING, BEACHING, LAUNCHING................85
MULTIPLE OUTBOARD MOTORS.......................87
SERVICING YOUR OUTBOARD MOTOR ................88
THE IMPORTANCE OF MAINTENANCE ............88
MAINTENANCE SAFETY......................................89
TOOL KIT and OWNER’S MANUAL.....................90

5
CONTENTS
EMERGENCY STARTER ROPE ............................ 90
MAINTENANCE SCHEDULE................................ 91
TRIM TAB ADJUSTMENT..................................... 93
MANUAL RELIEF VALVE .................................... 94
ENGINE COVER REMOVAL AND
INSTALLATION................................................... 94
Engine Oil Level Check ....................................... 95
Engine Oil Change ............................................... 97
Oil Filter Change.................................................. 98
Engine Oil Recommendations.............................. 99
Spark Plug Service ............................................. 100
Lubrication Points .............................................. 103
REFUELING........................................................... 105
FUEL RECOMMENDATIONS ............................. 107
Water Separator Inspection and Service ............ 108
Fuel Filter Inspection and Replacement............. 111
Portable Fuel Tank and Tank Filter Cleaning
(optional equipment) ....................................... 114
Anode Replacement ........................................... 115
Propeller Replacement ....................................... 115
Inspect After Operating...................................... 117
CLEANING AND FLUSHING ................................... 118
Cleaning and Flushing............................................. 118
STORAGE ....................................................................120
Fuel .....................................................................120
Engine Oil...........................................................122
HOISTING THE OUTBOARD MOTOR ...............122
STORAGE PRECAUTIONS ..................................122
REMOVAL FROM STORAGE..............................123
TRANSPORTING ........................................................124
WITH OUTBOARD MOTOR
INSTALLED ON BOAT......................................124
WITH OUTBOARD MOTOR
REMOVED FROM BOAT ..................................125
TAKING CARE OF UNEXPECTED PROBLEMS ....126
ENGINE WILL NOT START.................................126
HARD STARTING OR STALLS
AFTER STARTING.............................................129
ENGINE OVERHEATS..........................................130
FUSES .....................................................................131
Electric Starter Will Not Operate .......................131
Battery Will Not Charge.....................................131
Fuse Replacement...............................................131
OIL PRESSURE INDICATOR TURNS OFF AND
ENGINE SPEED IS LIMITED ............................133
OVERHEAT INDICATOR COMES ON AND
ENGINE SPEED IS LIMITED ............................134

6
CONTENTS
WATER SEPARATOR BUZZER SOUNDS......... 136
SUBMERGED OUTBOARD MOTOR.................. 136
TECHNICAL INFORMATION .................................. 138
Serial Number Locations......................................... 138
Battery ..................................................................... 139
Emission Control System Information .................... 139
Star Label ................................................................ 142
Specifications .......................................................... 144
CONSUMER INFORMATION................................... 147
Emission Control System Warranty ........................ 147
INDEX.......................................................................... 152

7
OUTBOARD MOTOR SAFETY
IMPORTANT SAFETY
INFORMATION
The TOHATSU BFT75A and
BFT90A outboard motors are
designed for use with boats that have
a suitable manufacturer’s power
recommendation. Other uses can
result in injury to the operator or
damage to the outboard motor and
other property.
Most injuries or property damage can
be prevented if you follow all
instructions in this manual and on the
outboard motor. The most common
hazards are discussed in this chapter,
along with the best way to protect
yourself and others.
Operator Responsibility
• It is the operator’s responsibility to
provide the necessary safeguards to
protect people and property. Know
how to stop the engine quickly in
case of emergency. Understand the
use of all controls.
• Stop the engine immediately if
anyone falls overboard, and do not
run the engine while the boat is
near anyone in the water.
• Always stop the engine if you must
leave the controls for any reason.
• Attach the emergency stop switch
lanyard securely to the operator.
• Always wear a PFD (Personal
Flotation Device) while on the
boat.
• Familiarize yourself with all laws
and regulations relating to boating
and the use of outboard motors.
• Be sure that anyone who operates
the outboard motor receives proper
instruction.
• Be sure the outboard motor is
properly mounted on the boat.
• Do not remove the engine cover
while the engine is running.

8
OUTBOARD MOTOR SAFETY
Refuel With Care
• Gasoline is extremely flammable,
and gasoline vapor can explode.
Refuel outdoors, in a well-
ventilated area, with the engine
stopped. Never smoke near
gasoline, and keep other flames and
sparks away.
• Refuel carefully to avoid spilling
fuel. Avoid overfilling the fuel
tank.
• After refueling, tighten the filler
cap securely. If any fuel is spilled,
make sure the area is dry before
starting the engine.
Carbon Monoxide Hazard
Exhaust contains poisonous carbon
monoxide, a colorless, odorless gas.
Breathing carbon monoxide can
cause loss of consciousness and may
lead to death.
If you run the engine in an area that is
confined, or even partly enclosed, the
air you breathe could contain a
dangerous amount of exhaust gas.
Never run your outboard inside a
garage or other enclosure.
Running the engine of your
outboard while in an
enclosed or partially
enclosed area can cause a
rapid build-up of toxic
carbon monoxide gas.
Breathing this colorless,
odorless gas can quickly
cause unconsciousness and
lead to death.
Only run your outboard
engine when it is located in
a well ventilated area
outdoors.

9
OUTBOARD MOTOR SAFETY
SAFETY LABEL LOCATION
The labels shown here contain important safety information. Please read them carefully. These labels are considered
permanent parts of your outboard motor. If a label comes off or becomes hard to read, contact an authorized TOHATSU
dealer for a replacement.
TILLER-HANDLE
(optional equipment)

10
OUTBOARD MOTOR SAFETY
PORTABLE FUEL TANK
(optional equipment)
FUEL CAUTION

11
CONTROLS AND FEATURES
CONTROL AND FEATURE IDENTIFICATION CODES
* Optional equipment
Refer to this chart for an explanation of the Type Codes used in this manual to identify control and feature applications.
Model BFT75A BFT90A
Type LRT□LRT□XRT□
Transom Height
(Shaft Length)
21.1 in (537 mm) ••
26.1 in (664 mm) •
Tiller Handle/Multi-Function Tiller Handle * * *
Remote Control * * *
Power Trim/Tilt •••
Tachometer * * *
Trim Meter * * *
TRL (Trolling) Control Switch * * *
TYPE CODE (example)
LR T □
Destination
Tilt System: T= Power Trim/Tilt
Control System: R= Remote Control
Transom Height (Shaft Length): L= 21.1 in (537 mm), X= 26.1 in (664 mm)

12
CONTROLS AND FEATURES
COMPONENT AND CONTROL LOCATIONS
OIL LEVEL DIPSTICK
OIL FILLER CAP
SPARK PLUG
(under ignition coil)
POWER TILT
SWITCH
FLUSH PORT
CONNECTOR
ENGINE OIL
DRAIN BOLT
ANTIVENTILATION
PLATE
GEAR OIL DRAIN SCREW
GEAR OIL
LEVEL SCREW
FRAME SERIAL
NUMBER
TILT LOCK
LEVER
COOLING WATER
INTAKE PORT
(each side)
NMEA INTERFACE
COUPLER
ENGINE COVER
LATCH (front)
STERN
BRACKET
MANUAL
RELIEF VALVE
ANODE
PROPELLER
(optional equipment)
EXHAUST PORT/WATER
OUTLET PORT
TRIM TAB
ANODE
(each side)
COOLING SYSTEM
INDICATOR
IDLE PORT
ENGINE COVER
LATCH (rear)
ENGINE COVER

13
CONTROLS AND FEATURES
Remote Controls (optional equipment)
(SIDE-MOUNT REMOTE CONTROL)
GEARSHIFT/THROTTLE CONTROL LEVER
POWER TRIM/TILT
SWITCH TRL (Trolling) CONTROL SWITCH*
CONTROL LEVER
FRICTION
ADJUSTER
EMERGENCY STOP
SWITCH LANYARD
EMERGENCY STOP
SWITCH CLIP
EMERGENCY STOP SWITCH
IGNITION SWITCH
KEY
IGNITION SWITCH
BUZZER
(inside) FAST IDLE LEVER
INDICATORS
(Oil pressure, Overheat,
Alternator, Malfunction)
NEUTRAL RELEASE LEVER
* For TRL (Trolling) control switch equipped type.

14
CONTROLS AND FEATURES
(PANEL-MOUNT REMOTE CONTROL)
GEARSHIFT/THROTTLE
CONTROL LEVER
POWER TRIM/TILT
SWITCH
NEUTRAL RELEASE
LEVER
FAST IDLE BUTTON
(SINGLE TOP-MOUNT REMOTE CONTROL)
GEARSHIFT/THROTTLE
CONTROL LEVER
POWER
TRIM/TILT
SWITCH
FAST IDLE
BUTTON
(DUAL TOP-MOUNT REMOTE CONTROL)
FAST IDLE
BUTTON
POWER TRIM/TILT
SWITCH (LEFT)
POWER TRIM/TILT
SWITCH (RIGHT)
GEARSHIFT/THROTTLE CONTROL LEVERS

15
CONTROLS AND FEATURES
(for TWO OUTBOARD MOTORS type)
(for TWO OUTBOARD
MOTORS type)
(for THREE OUTBOARD
MOTORS type)
CONTROL PANEL
(for PANEL-MOUNT/TOP-MOUNT SINGLE type)
BUZZER
IGNITION
SWITCH
EMERGENCY STOP
SWITCH CLIP
EMERGENCY STOP
SWITCH LANYARD
EMERGENCY
STOP SWITCH
CONTROL PANEL without indicators type
(for PANEL-MOUNT/TOP-MOUNT SINGLE type)
BUZZER
IGNITION
SWITCH
EMERGENCY STOP
SWITCH CLIP EMERGENCY STOP
SWITCH LANYARD
EMERGENCY
STOP SWITCH
INDICATORS
(Oil pressure, Overheat,
Alternator, Malfunction)
For the control panel without indicators type, use it
along with the NMEA2000-compatible device.
IGNITION
SWITCH KEY
IGNITION
SWITCH KEY

16
CONTROLS AND FEATURES
TILLER HANDLE (optional equipment)
INDICATORS
(Oil pressure, Overheat,
Alternator, Malfunction)
EMERGENCY STOP SWITCH
EMERGENCY STOP
SWITCH CLIP
EMERGENCY STOP
SWITCH LANYARD
GEARSHIFT LEVER
THROTTLE FRICTION
ADJUSTER
POWER TRIM/TILT SWITCH
THROTTLE GRIP
SPARE EMERGENCY STOP SWITCH CLIP
Store the spare emergency stop
switch clip in the tool bag.
IGNITION SWITCH STEERING FRICTION
ADJUSTING KNOB
IGNITION
SWITCH KEY

17
CONTROLS AND FEATURES
Multi-Function Tiller Handle (optional equipment)
INDICATORS
(Oil pressure, Overheat, Alternator, Malfunction)
STEERING FRICTION
ADJUSTING KNOB
IGNITION SWITCH KEY
IGNITION SWITCH
SPARE EMERGENCY STOP SWITCH CLIP
Store the spare emergency stop switch clip
in the tool bag.
EMERGENCY STOP
SWITCH CLIP
EMERGENCY STOP
SWITCH LANYARD
POWER TRIM/TILT SWITCH
EMERGENCY
STOP SWITCH
THROTTLE
GRIP
THROTTLE FRICTION
ADJUSTER
GEARSHIFT LEVER
TRL (Trolling) CONTROL
SWITCH

18
CONTROLS AND FEATURES
Portable Fuel Tank (optional equipment)
Fuel Tank Hose Assembly (standard equipment)
FUEL TANK
FUEL GAUGE
FUEL HOSE CONNECTOR
FUEL FILLER CAP VENT KNOB
FUEL HOSE JOINT
(outboard motor side)
FUEL PRIMING BULB
FUEL TANK HOSE
ASSEMBLY