TOHATSU MFS 3.5B User manual

MANUAL
2.5B
3.5B
MFS
OB No.003-11085-2
OWNER’S

Copyright © 2009 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.
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.
!

YOUR TOHATSU OUTBOARD MOTOR
OWNER REGISTRATION AND IDENTIFICATION
Upon purchasing this product, be sure that the WARRANTY CARD is correctly and
completely filled out and mailed to the addressee noted there on. This WARRANTY
CARD identifies you as the legal owner of the product and serves as your warranty
registration.
IF THIS PROCEDURE IS NOT FOLLOWED, YOUR OUTBOARD MOTOR WILL
NOT BE COVERED BY THE APPLICABLE LIMITED WARRANTY.
PRE-DELIVERY CHECK
Be sure that the product has been checked by an authorized TOHATSU dealer
before you take delivery.
Limited Warranty
Please refer to the TOHATSU outboard motor Limited warranty provided to you with
this product, the terms and conditions of which, as amended from time to time, are
incorporated by reference into the manual.

Serial Number
In the space below, please record the outboard motor's serial number (indicated
both on the lower motor cover and on the cylinder block). The serial number will be
needed in the event of theft or to quickly identifying the outboard motor type.
Serial Number :
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.
We hope you will enjoy your outboard motor and wish you good luck in your
boating adventures.
TOHATSU CORPORATION

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GENERAL SAFETY INFORMATION
SPECIFICATIONS
NAMES OF PARTS
INSTALLATION
1. Mounting the outboard motor on boat
PRE-OPERATING PREPARATIONS
1.Gasoline and engine oil
2.Break-in
3.ESG
ENGINE OPERATION
Before starting
1.Starting
2.Warming up the engine
3.Forward and reverse
4.Stopping
5.Trim angle
6.Tilt up, tilt down
7.Outboard motor positionin tilt up
REMOVING AND CARRYING THE OUTBOARD MOTOR
1.Removing the outboard motor
2.Carrying the outboard motor
3.Storing the outboard motor
TRAILERING
ADJUSTMENT
1.Steering friction
2.Throttle grip
INSPECTION AND MAINTENANCE
1.Daily inspection
2.Periodic inspection
3.Off-season storage
4.Pre-season check
5.Motor submerged in water
6.Cold weather precautions
7.Checking after striking underwater object
TROUBLESHOOTING
TOOL KIT AND SPARE PARTS
OPTIONAL ACCESSORIES
PROPELLER TABLE
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CONTENTS

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INDEX
1. SPECIFICATIONS
2. NAMES OF PARTS
3. INSTALLATION
4.PRE-OPERATING PREPARATIONS
5.ENGINE OPERATION
6.REMOVING AND CARRYING THE MOTOR
7.TRAILERING
8.ADJUSTMENT
9.INSPECTION AND MAINTENANCE
10.TROUBLESHOOTING
11.TOOL KIT AND SPARE PARTS
12.OPTIONAL ACCESSORIES
13.PROPELLER TABLE
GENERAL SAFETY INFORMATION

NOTICE : DANGER/WARNING/CAUTION/Note
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. 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.
EMERGENCY STOP SWITCH
The Emergency Stop Switch will stall the outboard motor when the stop switch
tether is pulled off. This stop switch tether can be attached to the operator of
the outboard motor to minimize or prevent injuries from the propeller in case the
operator falls overboard.
We highly recommend use of the Emergency Stop Switch tether.
Failure to observe will result in severe personal injury or death, and possibly property damage.
!
Note
This instruction provides special information to facilitate the use or maintenance of the
outboard motor or to clarify important points.
Failure to observe could result in personal injury or property damage.
!
!
Failure to observe could result in severe personal injury or death, or property damage.
GENERAL SAFETY INFORMATION
!
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 tether is coiled and can extended to a full 1,300 mm (51 inch.).

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.
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.
MAINTENANCE
As the owner of this outboard motor, you should be acquainted with correct
maintenance procedures. It is the operator's responsibility to perform all safety
checks and to ensure that all lubrication and maintenance 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.
MOUNTING
Outboard motor mounting must be performed by trained service person(s) using
lift or hoist with sufficient capacity.
!
SERIOUS INJURY IS LIKELY IF A PERSON IN THE WATER MAKES CONTACT WITH
A MOVING BOAT, GEAR HOUSING, PROPELLER, OR ANY SOLID DEVICE RIGIDLY
ATTACHED TO A BOAT OR GEAR HOUSING.

MODEL
Item 2.5B 3.5B
Overall Length mm (in) 690 (27.2)
Overall Width mm (in) 363 (14.3)
Overall Height S·L mm (in) 1,026 (40.4) · 1,153 (45.4)
Transom Height S·L mm (in) 435 (17.1) · 562 (22.1)
Weight S·L Kg (lb) 18.4 (41) · 19.4 (43)
Output kW (HP) 1.8 (2.5) 2.6 (3.5)
Max. Operating Range rpm 4,500-5,500 5,000-6,000
Idle Speed in Forward Gear rpm 1,200
Idle Speed in Neutral Gear rpm 1,300
Engine Type 4-Stroke
Number of Cylinder 1
Bore × Stroke mm (in) 55 × 36 (2.17 × 1.42)
Piston Displacement mL (Cu in) 85.5 (5.2)
Exhaust System Above propeller exhaust
Cooling System Water cooling
Engine Lubrication Splashing system
Startring System Manual starter
Ignition System Flywheel Magneto Digital C.D.I
Spark Plug NGK DCPR6E
Trim Position 4
Engine Oil mL (fl.oz.) NMMA FC-W certified 10W-30 or
API SF, SG, SH, SJ, SL or SM, Approx. 300 (10)
Gear Oil mL (fl.oz.) Genuine Gear Oil or API GL5,
SAE #80-90, Approx. 180 (6.1)
Clutch Dog clutch system (F-N)
Fuel Tank Capacity L (US gal) 1.0 (0.26) Integral tank
Gear Reduction Ratio 2.15 (13 : 28)
＊: with manual ※Specifications subject to change without notice.
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2.5B , 3.5B
SPECIFICATIONS

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Integral Fuel Tank
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2.5B , 3.5B
NAMES OF PARTS
①
②
③
④
⑤
⑥
⑦
⑧
⑨
⑩
Fuel Tank Cap
Tilt Handle
Top Cowl
Cowl Latch
Cooling Water Check Port
Steering Adjustment Screw
Anti Ventilation Plate
Anode
Propeller
Oil Plug (Lower) (Fill)
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20
Water Inlet
Oil Plug (Upper) (Level)
Drive Shaft Housing
Thrust Rod
Clamp Bracket
Clamp Screw
Throttle Grip
Shift Lever
Starter Handle
Air Vent Screw
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22
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23
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24
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25
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28
Choke Knob
Stop Switch
Tilt Stopper
Engine Oil Filter Cap
Engine Oil Drain Screw
Engine Oil Level Gauge
Air Vent Screw
Fuel Cock

Position ... Above keel line
Set engine at center of boat.
Transom matching
Be sure that the anti ventilation plate
of the outboard motor is below the
water surface.
If the above condition cannot be met
due to the shape of the bottom of your
boat, please consult your authorized
dealer.
To attach the outboard motor to the
boat, tighten the clamp screws by
turning their handles.
Also, use the bolts to secure the
outboard motor brackets on transom
board.
Secure the outboard motor with a rope
to prevent loss overboard.
Clamp screw
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1. Mounting the outboard motor on boat
INSTALLATION
Note
A rope is not included in the standard
accessories.
Boat Transom
Center of Boat
Bottom of hull
Anti Ventilation Plate
30-50mm
(1.2-2”)
●Before beginning the running test,
check that the boat with maximum
capacity loading floats on the water in
a proper attitude. Check the position
of water surface on the driveshaft
housing. If the water surface is near
the bottom cowling, in high waves,
water may enter the engine cylinders.
●Incorrect outboard motor mounting
height or existence of underwater
object(s), such as hull bottom
design, bottom surface conditions or
underwater accessories, can cause
water spray possibly reaching the
engine through an opening of the
bottom cowling during cruising.
Exposing the engine to such
conditions for extended periods can
lead to severe engine damage.
!
!
Most boats are rated and certified
in terms of their maximum allowable
horsepower, as shown on the boat’s
certification plate. Do not equip your boat
with an outboard motor that exceeds this
limit. If in doubt, contact your dealer.
Do not operate the outboard motor until it
has been securely mounted on the boat
in accordance with the instructions below.

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Notes
1. Apply sealing agent such as silicone
sealed between bolts and transom
board holes before tightening bolts.
2. Be sure to tighten mounting bolt
nuts to specified torque.
INSTALLATION
!
If the length of security line being used
is long enough to allow the outboard
to disengage off the boat transom but
is too short to not allow the outboard
to submerge behind the boat and stop
running, the outboard could continue
running and propel itself back into the
boat with the propeller rotating under
power. This exposes the occupants to
serious injury or death.
!
●Mounting the outboard motor
without following this manual can
lead to unsafe conditions such as
poor maneuverability, lack of control
or fire.
●Loose clamp screws and/or
mounting bolts can lead to release
off or displacement of the outboard
motor, possibly resulting in lost of
control and / or serious personal
injury. Be sure that fasteners are
tightened to the specified torque
(30 Nm (3.0kgf)13ft·lb). Check
fasteners for tightness from time to
time.
●Be sure to use outboard mounting
fasteners included in outboard
motor package or their equivalents
in terms of size, material, quality
and strength.
Tighten fasteners to the specified
torque (30 Nm (3.0kgf)13ft·lb). Test
cruise to check if fasteners are
tightened securely.
●Outboard motor mounting must
be performed by trained service
person(s) using lift or hoist with
sufficient capacity.
It is recommended to install upper
mounting bolts with bolt head at inside
surface of transom. Bolts with threaded
end at inside surface of transom can
cause personal injury.
!

Required Gasoline types
UNITED STATES AND CANADA:
Use a major brand of automotive
unleaded gasoline with a minimum
posted octane rating of 87. Mid-
grade automotive gasoline that
contain fuel injector cleaner are
preferred for added internal engine
cleanliness. Leaded gasoline is not
recommended.
INTERNATIONAL :
Use a major brand of automotive
unleaded gasoline with a minimum
posted octane rating of 91RON.
Automotive gasoline that contain
fuel injector cleaner are preferred for
added internal engine cleanliness.
Leaded gasoline is acceptable in
areas where unleaded gasoline is not
available.
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1. Gasoline and engine oil
Note
Use of low-quality gasoline results in
a short engine life as well as starting
difficulties and other engine problems.
We recommend use for Fuel stabilizer.
PRE-OPERATING PREPARATIONS
!
Do not fill the fuel tank over capacity.
The rise of gasoline temperature may
cause gasoline to expand which, if
overfilled, may leak through an air
vent screw when it is open. Leaking
gasoline is a dangerous fire hazard.
Consult an authorized dealer for details
on handling of gasoline, if necessary.
Gasoline and its vapors are very
flammable and can be explosive.
When carrying a fuel tank containing
gasoline:
●Close the air vent screw of fuel
tank cap, or gasoline vapor will be
emitted through the air vent screw,
creating a fire hazard.
●Do not smoke.
When or before refueling:
●Stop the engine, and do not start the
engine during refueling.
●Do not smoke.
●Be careful not to overfill fuel tank.
Wipe up any spilled gasoline
immediately.
When or before cleaning the gasoline
tank:
●Dismount fuel tank from the boat.
●Place the fuel tank away from every
source of ignition, such as sparks or
open flames.
●Do the work outdoors or in a well
ventilated area.
●Wipe up any spilled gasoline
immediately.
After cleaning gasoline tank:
●Wipe up any spilled gasoline
immediately.
●If the fuel tank is disassembled for
cleaning, reassemble carefully.
Imperfect assembly may cause a
fuel leak, possibly leading to fire or
explosion.
●Dispose of aged or contaminated
gasoline in accordance with local
regulations.
!

Engine Oil
Use only high quality 4-stroke
engine oil to insure performance and
prolonged engine life.
Use NMMA FC-W certified 4-stroke
engine oil below.
10W-30: is recommended for use in
all temperature.
You can also use oils that carry the
API rating of SF, SG, SH, SJ, SL, or
SM. Select the appropriate viscosity,
based on atmospheric temperature,
from the chart below.
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PRE-OPERATING PREPARATIONS
Note
Use of engine oils that do not meet
these requirements will result in
reduced engine life, and other engine
problems.
THE ENGINE OIL IS DRAINED FOR
SHIPPING FROM THE FACTORY. BE
SURE TO FILL THE ENGINE TO THE
PROPER LEVEL BEFORE STARTING
ENGINE. (TO PROPERLY FILL THE
ENGINE WITH OIL FOLLOW THE
INSTRUCTIONS IN SECTION 9 OF
THIS MANUAL)
!
10W−40
10W−30
Atmospheric temp.
˚C
˚F
40
96
30
86
20
68
10
50
0
32
-10
14
-20
-4
-30
-22
ENGINE
OIL

Your new outboard motor and lower
unit require break-in for the moving
components according to the
conditions described in the following
time table.
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2. Break-In
PRE-OPERATING PREPARATIONS
1-10min 10min-2hrs 2-3hrs 3-10hrs After 10hrs
Throttle Position Idle Less than 1/2
throttle
Less than 3/4
throttle 3/4 throttle Full throttle available
Speed Approx.
3,000 rpm max
Full throttle run
allowed for 1 min
every 10 min
Approx.
4,000 rpm.
Full throttle run
allowed for 2 min
every 10 min
Note
Proper break-in allows outboard
motor to deliver it full performance for
longer service life.
Do not operate the outboard motor
in closed area or area with no forced
ventilation.
Exhaust gas emitted by this outboard
motor contains carbon monoxide that
will cause death if inhaled continuously.
Inhaling the gas initially causes
symptoms such as feeling of sickness,
drowsiness and headache.
During operation of the outboard motor:
●Keep peripheral area well ventilated.
●Always attempt to stay on the
windward side of emission.
!
Operating the outboard motor without
break-in can shorten service life of the
product.
If any abnormality is experienced
during the break-in:
●Discontinue the operation
immediately.
●Have the dealer check the product
and take proper action(s) if
necessary.
!

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ESG is a device to prevent over
revolution of the engine (more than
approximately 6,300 rpm).
If you sense that the ESG is activated
return to shore at a reduced speed
(rpm).
Possible causes of ESG activation are
: Worn, broken, bent propeller and
shear pin. Slipping propeller rubber,
Making sharp turns at high speeds,
Trim angle.
Note
If the engine speed drops frequently
after restarting the engine, please
contact your dealer.
3. ESG (A device preventing over revolution)
PRE-OPERATING PREPARATIONS

Air vent screw
Before starting engine for the first time
after reassembling engine or off-season
storage, disconnect stop switch lock
and pull the starter handle completely
out approximately 10 times in order to
prime the oil pump.
① Loosen the air vent screw on the
tank cap.
② Open the fuel cock.
③ Be sure to install the stop switch
lock to the stop switch and
connect the coil cord to a part of
the operator's body by the hook.
④ Make sure that the shift lever is in
the Neutral position.
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Before starting
1. Starting
Note
The engine will not start unless
the switch lock has been properly
connected into the emergency stop
switch.
If the engine starts in gear, do not use
it. Contact an authorized dealer.
!
ENGINE OPERATION
!
In case engine starts in gear, do not
start cruising. Stop engine immediately
and consult an authorized dealer.
!
Do not operate the engine with gear
case out of water.
Severe personal injury, or engine
damage will result.
Air vent screw
Fuel cock
Throttle grip
Shift
lever
Hook
SLOW
HIGH
Choke
knob
Stop switch lock

⑤Set the throttle grip to "START"
position.
⑥Pull the choke knob fully. (When
the motor has been warmed up,
it is not necessary to operate the
choke knob.)
⑦Gently pull the starter handle
until you feel slight resistance
(engagement), and then quickly
and strongly pull the handle
without a rest.
⑧When the motor starts, push the
choke knob back. (in the case the
choke knob is used.)
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ENGINE OPERATION
Note
When the motor has been warmed up,
set the throttle grip to the "RE-START"
position.
Quickly Slowly
Note
When warming up the engine in cold
weather , set the choke knob to half
opened position if necessary.
Note
Start-in-gear protection prevents
engine from starting at other than
neutral shift. In-gear starting of engine
will move the boat immediately,
potentially leading to falling down or
causing passenger(s) to be thrown
overboard.

Cowl latch
If the recoil starter fails to operate
◎Remove the top cowl and the recoil
starter.
Removing the recoil starter
①Loosen the three bolts (A,B,C)
fastening the tank. (Don't remove
the tank fastening bolts.)
②Remove the three bolts (D,E,F)
fastening the recoil starter.
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ENGINE OPERATION
③Remove the recoil starter.
④Tighten the three bolts (A,B,C)
fastening the tank and one bolt (D)
fastening the recoil starter.
◎ Confirm that the shift lever is at
Neutral (N) position.
◎ Wrap a rope around the starter
pulley then pull quickly to start.
◎Use a 10 mm socket wrench as a
rope handle.
◎Reinstall top cowl after engine
starts.
A
B
C
E
F
D
A
B
C
D