TOHATSU BFT 90A User manual

BFT 75A
90A
OWNER’S MANUAL
000000000
Printed in Japan
31ZY9T00
00X31-ZY9-T000
BFT 75A
90A
TOHATSU CORPORATION
Address : 5-4,AZUSAWA 3-CHOME ITABASHI-KU,
TOKYO 174-0051
Phone : [phone]
FAX : [phone]
URL : www.tohatsu.co.jp

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.
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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
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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.
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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.............................................................. 18
Side-Mount Type ................................................. 18
Ignition Switch................................................ 18
Emergency Stop Switch Clip and Emergency
Stop Switch .................................................. 18
Gearshift/Throttle Control Lever .................... 19
Fast Idle Lever ................................................ 20
Panel-Mount Type................................................ 21
Ignition Switch................................................ 21
Emergency Stop Switch Clip and Emergency
Stop Switch .................................................. 22
Gearshift/Throttle Control Lever .................... 23
Fast Idle Button............................................... 24
Top-Mount Type .................................................. 25
Ignition Switch................................................ 25
Emergency Stop Switch Clip and Emergency
Stop Switch .................................................. 25
Gearshift/Throttle Control Lever .................... 26
Fast Idle Button............................................... 28
TRL (Trolling) Control Switch
(optional equipment)...........................................29
Power Trim/Tilt Switch ........................................30
Power Tilt Switch .................................................31
Manual Relief Valve.............................................31
Tilt Lock Lever.....................................................32
Engine Cover Latch (front/rear) ...........................32
Trim Tab ...............................................................32
INSTRUMENTS .......................................................33
Trim Meter (optional equipment) .........................33
Tachometer (optional equipment) ........................33
Fuel Gauge (optional equipment) .........................33
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4
CONTENTS
INDICATORS........................................................... 34
Alternator (ACG) Indicator.................................. 34
Malfunction Indicator........................................... 34
Oil Pressure Indicator........................................... 35
Overheat Indicator................................................ 35
Cooling System Indicator..................................... 36
OTHER FEATURES ................................................ 37
Water Separator Buzzer ....................................... 37
Overrev Limiter.................................................... 37
Portable Fuel Tank (optional equipment) ............ 37
Fuel Filler Cap Vent Knob................................... 38
Fuel Priming Bulb ................................................ 38
Anodes.................................................................. 39
NMEA Interface Coupler..................................... 40
Operating Hour Notification System ................... 40
BEFORE OPERATION ................................................. 43
ARE YOU READY TO GET UNDERWAY? ......... 43
IS YOUR OUTBOARD MOTOR 
READY TO GO? ................................................... 43
OPERATION..................................................................45
SAFE OPERATING PRECAUTIONS .....................45
BREAK-IN PROCEDURE........................................45
PORTABLE FUEL TANK (optional equipment).....46
FUEL HOSE CONNECTIONS.................................46
FUEL PRIMING........................................................48
INFREQUENT OR OCCASIONAL USE ................48
STARTING THE ENGINE .......................................49
Side-Mount Type..................................................49
Panel-Mount Type ................................................52
Top-Mount Type...................................................54
EMERGENCY STARTING......................................57
STOPPING THE ENGINE........................................60
Emergency Engine Stopping ................................60
Normal Engine Stopping ......................................61
GEARSHIFT AND THROTTLE OPERATION ......63
STEERING ................................................................64
CRUISING.................................................................65
SHALLOW WATER OPERATION.........................68
MOORING, BEACHING, LAUNCHING................69
MULTIPLE OUTBOARD MOTORS.......................70
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5
CONTENTS
SERVICING YOUR OUTBOARD MOTOR................ 71
THE IMPORTANCE OF MAINTENANCE............ 71
MAINTENANCE SAFETY...................................... 72
TOOL KIT and OWNER’S MANUAL .................... 73
EMERGENCY STARTER ROPE ............................ 73
MAINTENANCE SCHEDULE................................ 74
TRIM TAB ADJUSTMENT..................................... 76
MANUAL RELIEF VALVE .................................... 77
ENGINE COVER REMOVAL AND
INSTALLATION................................................. 77
Engine Oil Level Check ............................................ 78
Engine Oil Change .................................................... 80
Oil Filter Change ....................................................... 81
Engine Oil Recommendations................................... 82
Spark Plug Service .................................................... 83
Lubrication Points ..................................................... 86
REFUELING............................................................. 88
FUEL RECOMMENDATIONS ............................... 90
Water Separator Inspection and Service ................... 91
Fuel Filter Inspection and Replacement.................... 94
Portable Fuel Tank and Tank Filter Cleaning
(optional equipment) .............................................. 97
Anode Replacement .................................................. 98
Propeller Replacement .............................................. 98
Inspect After Operating ........................................... 100
CLEANING AND FLUSHING....................................101
Cleaning and Flushing .................................101
STORAGE ....................................................................103
Fuel .....................................................................103
Engine Oil...........................................................105
HOISTING THE OUTBOARD MOTOR ...............105
STORAGE PRECAUTIONS ..................................105
REMOVAL FROM STORAGE..............................106
TRANSPORTING ........................................................107
WITH OUTBOARD MOTOR 
INSTALLED ON BOAT......................................107
WITH OUTBOARD MOTOR 
REMOVED FROM BOAT ..................................107
TAKING CARE OF UNEXPECTED PROBLEMS ....108
ENGINE WILL NOT START.................................108
HARD STARTING OR STALLS AFTER 
STARTING...........................................................111
ENGINE OVERHEATS..........................................112
FUSES .....................................................................113
Electric Starter Will Not Operate .......................113
Battery Will Not Charge.....................................113
Fuse Replacement...............................................113
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6
CONTENTS
OIL PRESSURE INDICATOR TURNS OFF AND
ENGINE SPEED IS LIMITED............................ 115
OVERHEAT INDICATOR COMES ON AND
ENGINE SPEED IS LIMITED............................ 116
WATER SEPARATOR BUZZER SOUNDS......... 117
SUBMERGED OUTBOARD MOTOR.................. 118
TECHNICAL INFORMATION .................................. 120
Serial Number Locations.................................... 120
Battery ................................................................ 121
Emission Control System Information............... 121
Star Label ........................................................... 124
Specifications ..................................................... 126
CONSUMER INFORMATION................................... 129
Emission Control System Warranty................... 129
INDEX.......................................................................... 134
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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.
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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.
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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.
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10
OUTBOARD MOTOR SAFETY
PORTABLE FUEL TANK 
(optional equipment)
FUEL CAUTION
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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 LRTA LRTA XRTA
Transom Height
(Shaft Length)
21.1 in (537 mm)  
26.1 in (664 mm) 
Tiller Handle ***
Remote Control ***
Power Trim/Tilt 
Tachometer ***
Trim Meter ***
TRL (Trolling) Control Switch ***
TYPE CODE (example)
LR T A
Destination: A= American
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)
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12
CONTROLS AND FEATURES
COMPONENT AND CONTROL LOCATIONS
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 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
PRODUCT
IDENTIFICATION
NUMBER
TILT LOCK
LEVER
COOLING WATER
INTAKE PORT
(each side)
NMEA INTERFACE
COUPLER
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13
CONTROLS AND FEATURES
Remote Controls (optional equipment)
(SIDE-MOUNT REMOTE CONTROL)
GEARSHIFT/THROTTLE
CONTROL LEVER
POWER TRIM/TILT
SWITCH
SPARE EMERGENCY
STOP SWITCH CLIP
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
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14
CONTROLS AND FEATURES
(PANEL-MOUNT REMOTE CONTROL)
CONTROL PANEL (for PANEL-MOUNT type)
GEARSHIFT/THROTTLE
CONTROL LEVER
POWER TRIM/TILT
SWITCH
NEUTRAL RELEASE
LEVER
FAST IDLE BUTTON
BUZZER
IGNITION
SWITCH
EMERGENCY STOP
SWITCH CLIP
EMERGENCY STOP
SWITCH LANYARD
EMERGENCY
STOP SWITCH
INDICATORS 
(Oil pressure, Overheat,
Alternator, Malfunction)
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15
CONTROLS AND FEATURES
(SINGLE TOP-MOUNT REMOTE CONTROL)
CONTROL PANEL 
(for TOP-MOUNT SINGLE type)
(DUAL TOP-MOUNT REMOTE CONTROL)
(for TOP-MOUNT DUAL type)
GEARSHIFT/THROTTLE
CONTROL LEVER
POWER
TRIM/TILT
SWITCH
FAST IDLE
BUTTON
BUZZER
IGNITION
SWITCH
EMERGENCY STOP
SWITCH CLIP
EMERGENCY STOP
SWITCH LANYARD
EMERGENCY
STOP SWITCH
INDICATORS 
(Oil pressure, Overheat,
Alternator, Malfunction)
FAST IDLE
BUTTON
POWER TRIM/TILT
SWITCH (LEFT)
POWER TRIM/TILT
SWITCH (RIGHT)
GEARSHIFT/THROTTLE
CONTROL LEVERS
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16
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
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17
CONTROLS AND FEATURES
Trim Meter
(optional equipment)
Tachometer
(optional equipment)
TRL (Trolling) Control Switch
Panel
(optional equipment)
TRL (Trolling) CONTROL SWITCH
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18
CONTROLS AND FEATURES
CONTROLS
Side-Mount Type
Ignition Switch
The ignition switch controls the
ignition system and the starter motor.
Turning the ignition switch key to the
START position operates the starter
motor. The key automatically returns
to the ON position when released
from the START position.
The ignition switch can be used to
start the engine only when the control
lever is in the N (neutral) position
(p.49) and the emergency stop switch
clip is in the emergency stop switch.
Turning the ignition switch to the
OFF position stops the engine.
Emergency Stop Switch Clip and
Emergency Stop Switch
IGNITION
SWITCH
ON START
OFF
EMERGENCY STOP SWITCH
EMERGENCY STOP
SWITCH CLIP
EMERGENCY
STOP SWITCH
LANYARD
EMERGENCY STOP
SWITCH CLIP
EMERGENCY
STOP SWITCH
LANYARD
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