TOHATSU F40 User manual

1
Installation Manual 2016
Multi-Function Tiller Handle Kit installation
Manual
F40/50
■ Parts List
Ref. No. Part No. Part name Q’ty
3KYQ63000-1 TILLER HANDLE KIT 1 set
1– TILLER HANDLE ASSY 1
29153E3-1040 STUD 2
3930403-1000 NYLON NUT 2
49401E3-1000 WASHER 2
53GF-62004-0 CORD HOLDER 1
63T5-06437-0 TAPPING SCREW 1
73V5-62442-0 NYLON NUT 1
83AC-63012-0 GRIP 1
9346-66334-0 STOPPER 1
Ref. No. Part No. Part name Q’ty
10 3KY-62441-0 FRICTION LEVER 1
11 3GF-62449-0 DISC 2
12 3KY-62447-0 PLATE 1
13 3V1-60108-0 BOLT (stud) 2
14 3B7-63730-0 WASHER 1
15 3R3-62443-0 WASHER 1
16 3GF-62445-0 BOLT 1
17 346-62127-0 CAP NUT 2
18 – TILLER HANDLE KIT MANUAL 1
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3KY-63300-1
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22016 Installation Manual
Preface
This manual covers the Multi-Function Tiller Handle Kit installation procedure.
Read this manual carefully and preform the correct procedures. Only Authorized Dealers should
perform the set-up and installation.
GENERAL SAFETY INFORMATION
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.
Attention.
DANGER
Indicates the presence of a hazard
which, if ignored, will result in
severe injury or death.
Contents
Parts List …………………………………………………………………………………………………………………… 1
Dimensions for full tilt up and steering ……………………………………………………………………………… 3
Preparation ………………………………………………………………………………………………………………… 4
Multi-function Tiller Handle installation ……………………………………………………………………………… 4
Shift/Throttle cable adjustment ………………………………………………………………………………………… 6
Friction Lever Installation ………………………………………………………………………………………………… 8
Friction Lever adjustment and operation ……………………………………………………………………………… 8
Operation inspection ……………………………………………………………………………………………………… 9
Wiring Diagram …………………………………………………………………………………………………………… 10
WARNING
Indicates the presence of a hazard
or an unsafe activity which, if
ignored, could result in severe
injury or death.
CAUTION
Indicates the presence of a hazard
or an unsafe activity which, if
ignored, could result in minor
personal injury or damage to the
products or facilities.
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3
Installation Maual 2016
Dimensions for full tilt up and steering
Be sure to confirm that NO parts will interfere with the boat or transom when the motor is at full tilt.
Do NOT install if any parts that could interfere with the boat or transom.
1382
STEERING ANGLE
Max. Tilt angle
600
419
404
717
69
S:740 L:873 UL:987
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42016 Installation Manual
Preparation
1. Remove bolt 1 and remote cont. cable stay
cover 2.
2. Remove bolt 4 and cable clip 5.
3. Remove cable grommet 6.
Multi-function Tiller Handle
installation
1. Install stud bolt 1.
3. Insert main harness 4 from tiller handle, shift
cable 5 and throttle cable 6.
Nylon nut
27 N · m (20 lb·ft) [2.7 kgf·m]
Remove air silencer 3 to remove
remote control cover.
6
1
5
2
3
4
1
1
3
2
6
5
4
Use double nut to install stud bolt.
2. Install Multi-function tiller handle Assy 2, nylon
nut and washer (2pcs.) 3.
Stud bolt
27 N · m (20 lb·ft) [2.7 kgf·m]
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5
Installation Maual 2016
8
7
9
0
6
5
4
q
w
r
e
t
4. Open cable terminal holder cover 7, connect
three connectors 8, and then close cover.
5. Install cable clip 9 to mount battery cable 0 and
main harness 4.
Install grommet, and insert shift cable 5, throttle
cable 6 to cable clip.
6. Install remote cont. cable stay cover q, and then
install air silencer w.
7. Install code holder e to multi function tiller
handle, put in battery cord r and fuel hose t.
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62016 Installation Manual
Shift/Throttle cable adjustment
1. Place shift lever 1 at neutral position.
• Cable joints are in the outboard
box.
• After adjusting remote control
cable joint, fix it with remote
control cable fully pushed in.
CAUTION
Shift lever cannot work unless
throttle is fully closed. Do not force
the shift.
WARNING
Screw-in remote control cable joint
at least 12 mm b.
R
N
F
1
2
4
5
b
3
2. Set shift arm 2 to forward (F), neutral (N),
reverse (R) and then to neutral (N) positions.
3. Set throttle cam 3 to full close position.
4. Adjust screw-in length of cable joint 4 so that
hole of cable joint is brought to throttle arm pin
and shift arm pin 5.
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7
Installation Maual 2016
R
N
F
6
7
5. Lock joint with nut 6, put in on the pin, and
secure with washer and R-pin 7.
6. Check the shift lever operation.to forward (F),
neutral (N) and reverse (R) position.
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82016 Installation Manual
· Washer (Nylon) 2
· Washer 3
· Disk 4
· Plate 5
· Bolt (2pcs.) 6
· Disk 7
· Friction Lever 8
· Nylon nut 9
· Grip 0
· Stopper q
Do not apply grease to washers.
Friction Lever adjustment and
operation
· Move friction lever towards starboard side a
and tighten nylon nut 1 to adjust maximum
friction.
· Move friction lever towards port side b and
confirm steering moves easily.
WARNING
• Do not release tiller handle while
operating. Friction lever is not for
holding steering completely.
• Do not overtighten the steering
friction or it could result in
difficulty of movement resulting
in the loss of control causing an
accident and could lead to severe
injury.
Tighten bolt 1 until the length of a
would be 18.5 mm.
CAUTION
Do not tighten bolt until more than
one thread of bolt c can be seen
above the nut or if could result in
interfere with tiller handle.
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c
1
1
a
b
1a
Friction Lever Installation
1. Install following parts, following steps.
· bolt 1
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9
Installation Maual 2016
Operation inspection
· Install stop switch lanyard 1.
· Place shift lever 2 into neutral (N) position.
· Insert key 3 and place it into “OFF” position.
· PTT Switch 4
Press the “UP” and “DOWN” switch and confirm
PTT is working correctly.
· Engine rotation
Start engine and confirm whether idling rpm is
stable.
· Each time the main switch key is pressed in the
above manner, engine speed changes as follow
chart.
· Also, confirm whether engine rpm accelerates
smoothly.
At stating
850 rpm →750 rpm →650 rpm
↑   ↓
950 rpm ←850 rpm ←750 rpm
· Neutral switch
Confirm that the engine does not start except
when in neutral.
· Stop Switch
Confirm that engine will stop when turn the key
into “OFF” position or by removing the stop
switch lanyard.
CAUTION
• Do not operate the engine with
gear case out of water.
• Shift lever cannot work unless
throttle is fully closed. Do not
force to change the shift.
• Be sure to confirm that NO parts
will interfere with the boat or
transom when the motor is at full
tilt.
R
N
F
2
3
1
4
OFF
ON
START
PUSH TO IDLE CHANGE
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10 2016 Installation Manual
MAINSWITCH
WARNINGLAMP
OVERHEATBUZZER
STOPSWITCH
PTTSWITCH
ToTACHOMETER
(option)
liO
taeHrevO
yrettaB
BBlack
LBlue
Br Brown
GGreen
RRed
WWhit
e
YYellow
PPink
Lg LightGreen
Sb Sky Blue
R/
YRed/Yellow
G/
RGreen/Red
Y/
RYellow/Red
*"/"meanscordswithstripedcolors.
Lg
Y
B
Br
R
L
G
W
RR
R
R
R
R
L
GL
B
Br
PP
Sb Sb
Lg
YY
P
Sb
R
B
B
Br Br
B
Br
P
R
Sb
R/Y
G/R
Y/R
RR
G/R
G/R
Y/R
Y/R
R/Y
Lg
R/Y
R
G
Lg Y/R
G/R
R
Wiring Diagram
Contact
TOHATSU CORPORATION
Adress: 5-4, Azusawa 3-Chome, Itabashi-ku, Tokyo, Japan
Phone: [phone]
Copyright c 2016 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.
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