TOHATSU MFS 9.8A3 Owner's Manual
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TOHATSU MFS 9.8A3 Owner's Manual

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OWNER'S
MANUAL
8A3
MFS
9.8A3
OB No.003-11082-5

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  • Page 1 OWNER’S MANUAL 9.8A3 OB No.003-11082-5...
  • Page 2 INJURY OR DEATH. KEEP THIS MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE. 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...
  • Page 3 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.
  • Page 4 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.

  • Page 5: Table Of Contents

    CONTENTS GENERAL SAFETY INFORMATION SPECIFICATIONS NAMES OF PARTS INSTALLATION 1. Mounting the outboard motor on boat 2. Installing the remote control devices 3. Installing the battery PRE-OPERATING PREPARATIONS 1.Gasoline and engine oil 2.Break-in 3.Engine oil warning lamp 4.ESG ENGINE OPERATION Before starting 1.Starting 2.Warming up the engine...
  • Page 7 INDEX GENERAL SAFETY INFORMATION 1. SPECIFICATIONS 2. NAMES OF PARTS 3. INSTALLATION 4.PRE-OPERATING PREPARATIONS 5.ENGINE OPERATION 6.REMOVING AND CARRYING THE OUTBOARD MOTOR 7.TRAILERING 8.ADJUSTMENT 9.INSPECTION AND MAINTENANCE 10.TROUBLESHOOTING 11.TOOL KIT AND SPARE PARTS 12.OPTIONAL ACCESSORIES 13.PROPELLER TABLE...

  • Page 8: General Safety Information

    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,"...
  • Page 9 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.

  • Page 10: Specifications

    SPECIFICATIONS MF , EF , EP 9.8A3 MODEL Item 975 (38.4) 590 (23.2) Overall Length mm (in) Overall Width mm (in) 354 (13.9) 320 (12.6) 1,035 (40.7) · 1,162 (45.7) · 1,289 (50.7) Overall Height S·L·UL mm (in) 435 (17.1) · 562 (22.1) · 689 (27.1) Transom Height S·L·UL mm (in) S Kg (lb)
  • Page 11 SPECIFICATIONS EFT , EPT 9.8A3 MODEL Item Overall Length mm (in) 975 (38.4) 590 (23.2) Overall Width mm (in) 354 (13.9) 320 (12.6) 1,035 (40.7) · 1,162 (45.7) · 1,289 (50.7) Overall Height S·L·UL mm (in) 435 (17.1) · 562 (22.1) · 689 (27.1) Transom Height S·L·UL mm (in) S Kg (lb)

  • Page 12: Names Of Parts

    NAMES OF PARTS MF , EF , EP EP type only MF and EF type only. EF type only. Tilt Handle Drive Shaft Housing Primer Bulb Top Cowl Thrust Rod Fuel Tank Cap Cowl Latch Clamp Bracket Air Vent Screw Cooling Water Check Port Clamp Screw Fuel Connector...
  • Page 13 NAME OF PARTS EFT , EPT EPT type only EFT type only. EPT type only. Tilt Handle Drive Shaft Housing Primer Bulb Top Cowl Clamp Bracket Fuel Tank Cap Cowl Latch Clamp Screw Air Vent Screw Cooling Water Check Port Power tilt switch Fuel Connector Oil Drain Bolt...

  • Page 14: Installation

    INSTALLATION ������� 1. Mounting the outboard motor on boat Before beginning the running test, ������� check that the boat with maximum capacity loading floats on the water in a proper attitude. Check the position Most boats are rated and certified of water surface on the driveshaft in terms of their maximum allowable housing.
  • Page 15 INSTALLATION Note MF, EF, EP type To attach the outboard motor to the It is recommended to install upper boat, tighten the clamp screws by mounting bolts with bolt head at turning their handles. inside surface of transom. Bolts with Also, tighten the bolts.

  • Page 16: Eft/Ept Type

    INSTALLATION EFT, EPT type (Power tilt model) Note 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. Notes 1. Apply sealing agent such as silicone sealed between the bolts and transom board holes before tightening the bolts.

  • Page 17: Installing The Remote Control Devices

    INSTALLATION 2. Installing the remote control devices Fitting of Remote Control Cable to It is recommended that you consult Engine. w i t h y o u r a u t h o r i z e d d e a l e r f o r installation and adjustment of the Note remote control device.

  • Page 18: Connecting The Cord Assembly

    INSTALLATION ������� Connecting the Cord assembly (Wiring Harness) Do not disconnect cord ass'y when engine is in operation, or engine will go Pass the Cord assembly from the out of control. Remote control box through the hole in the Lower motor cover and cover the wire ends with the Sleeve (provided in a tool bag) and then c o n n e c t t h e e l e c t r i c t e r m i n a l s...

  • Page 19: Ept Model

    INSTALLATION EPT model Green Blue Blue Green Brown Blue Black Brown Yellow Brown Black Pink Sky blue Black Brown Connect the positive cord (+) to the ������� positive terminal (+) of the battery, Make sure that the battery cords do and then connect the negative not get stuck between the outboard cord (−).

  • Page 20: Installing The Battery

    INSTALLATION ������� 3. Installing the battery Battery electrolyte contains sulfuric acid P l a c e t h e b a t t e r y b o x i n a and thus is hazardous, causing a burn convenient position away from if it comes in contact with your skin, or water spray.

  • Page 21: Pre-Operating Preparations

    PRE-OPERATING PREPARATIONS ������ 1. Gasoline and engine oil Consult an authorized dealer for details Required Gasoline types on handling of gasoline, if necessary. UNITED STATES AND CANADA: Gasoline and its vapors are very flammable and can be explosive. Use a major brand of automotive unleaded gasoline with a minimum When carrying a fuel tank containing posted octane rating of 87.
  • Page 22 PRE-OPERATING PREPARATIONS Note Engine Oil U s e o n l y h i g h q u a l i t y 4 - s t r o k e Use of engine oils that do not meet engine oil to insure performance and these requirements will result in prolonged engine life.

  • Page 23: Break-In

    PRE-OPERATING PREPARATIONS 2. Break-in Your new outboard motor and lower ������� unit require break-in for the moving c o m p o n e n t s a c c o r d i n g t o t h e Operating the outboard motor without conditions described in the following break-in can shorten service life of the...

  • Page 24: Engine Oil Warning Lamp

    PRE-OPERATING PREPARATIONS 3. Engine oil warning lamp 4. ESG (A device preventing over revolution) Oil pressure is required to lubricate ESG is a device to prevent over internal engine parts. revolution of the engine (more than When the warning lamp (Red) is off, it approximately 6,250 rpm).

  • Page 25: Engine Operation

    PRE-OPERATING PREPARATIONS ENGINE OPERATION Before starting Attach the fuel connector to the Before starting engine for the first time engine connector. after reassembling engine or off-season The arrow mark on the primer bulb storage, disconnect stop switch lock should be facing the engine. and pull the starter handle completely out approximately 10 times in order to prime the oil pump.
  • Page 26 ENGINE OPERATION MF, EF and EFT type Place the shift lever in the Neutral Set the throttle grip to "START" position. position. Be sure that the shift is in Neutral when starting the engine. This model is provided with start in gear protection.
  • Page 27 ENGINE OPERATION MF type EP and EPT type Engine is equipped with a compression Insert the main switch key. release mechanism. Set the control lever in the Neutral Pull the starter handle slowly until position. you feel engagement, keep pulling Raise the Free accel lever a little till you feel less resistance.
  • Page 28 ENGINE OPERATION ������� Loosen the screw for starter lock wire. Do not keep turning starter motor for over 5 seconds, or the battery may be consumed, potentially making the engine starting impossible and/or damaging the starter. If cranking over 5 seconds fails to start engine, return main switch to "ON", and crank engine again after 10 seconds or more.
  • Page 29 ENGINE OPERATION Confirm that the shift lever is at If the choke solenoid fails to neutral position. operate (EP and EPT type only) Wrap a rope around the starter pulley then pull quickly to start. Remove the top cowl. Use a 10 mm socket wrench as a Close the choke plate by finger.

  • Page 30: Engine Operation 25

    ENGINE OPERATION 2. Warming up the engine Engine speeds Idling speed after warming up. War m the engine at low engine Remark: In case of cold engine speeds for about three minutes. This starting, idling speed is increased allows the lubricating oil to circulate to about 300 rpm for several minutes.

  • Page 31: Forward And Reverse

    ENGINE OPERATION 3. Forward and reverse MF, EF and EFT type ������� Before shifting into forward or reverse, make sure that boat is properly moored and outboard motor can be steered fully to the right and left. Make sure that no swimmer(s) is ahead or astern of the boat.
  • Page 32 ENGINE OPERATION ������� Forward Quickly push the control lever to the Be sure to warm up engine well before Forward (F) position 32˚, where the starting cruise. Operating cold engine gear is connected, while lifting up on may cause damage to your motor. the lock button located at the bottom of the control lever grip.

  • Page 33: Stopping

    ENGINE OPERATION 4. Stopping EP and EPT type MF, EF and EFT type START Stop switch Stop Switch Lock Stop switch lock Turn the throttle grip to the slow position. Put the shift lever in the Neutral position. Run the engine for 2-3 minutes at idling speed if it has been running at full speed.

  • Page 34: Trim Angle

    ENGINE OPERATION ������� 5. Trim angle Do not put hand or finger in between The trim angle of the outboard motor outboard motor body and clamp can be adjusted to suit the transom bracket when adjusting trim angle to angle of the hull, and load conditions. prevent injury in case the outboard motor body falls.
  • Page 35 ENGINE OPERATION EFT and EPT type Improper Trim Angle (bow rise too high) If the trim angle is excessive, the bow will rise out of the water and the speed will decrease. EFT model Furthermore, the bow may sway or the bottom may slam the water while cruising.
  • Page 36 ENGINE OPERATION MF, EF type Stop the engine. Shift the outboard into neutral. Raise the engine to the tilt up position. Change the thrust rod position. Gentry lower the outboard. Thrust Rod Transom angle settings Higher Tilt release position Lower �������...
  • Page 37 ENGINE OPERATION Lock the tilt with the Tilt stopper after the outboard motor has been EPT type Operate the Power Tilt switch and tilted up. tilt the outboard motor up. (The Main Switch must be "ON".) Tilt Stopper Manual tilting If the battery is dead, and the Power Tilt Switch inoperative, The outboard motor can also be...
  • Page 38 ENGINE OPERATION ������� EFT/EPT type The provided Power tilt makes tilt- The power Tilt can be set to any trim up/down electrically. It may be used angle, however, avoid cruising with the as a power trim and tilt when the outboard motor tilted in the tilt range.

  • Page 39: Tilt Up, Tilt Down And Shallow Water Operation

    ENGINE OPERATION 6. Tilt up, tilt down and shallow water operation Tilt down Slightly tilt the motor up, and pull the tilt lever toward you to release the tilt- ������� lock. Then lower the motor slowly. When tilting up or down, be careful not to place your hand between the swivel bracket and the stern bracket.
  • Page 40 ENGINE OPERATION Tilt down Move the tilt lock knob to the unlock position. Raise the outboard to the tilt release position. Gently lower the outboard. Tilt lock knob in lock position Tilt lock knob in unlock position Tilt up position Tilt release position...

  • Page 41: Shallow Water Operation

    ENGINE OPERATION 7. Shallow water operation MF, EF type Shallow water running position ������� With the shift lever in Neutral or Forward, tilt the motor up slowly During shallow water operation, be by about 40˚ and then lower the careful not to place your hand between the swivel bracket and the stern bracket.
  • Page 42 ENGINE OPERATION EP type Setting shallow water drive Releasing shallow water drive Stop the engine. Stop the engine. Shift the outboard into forward. Tilt the outboard up to the tilt Tilt the outboard up to one of the release position. shallow water drive positions.

  • Page 43: Removing And Carrying The Outboard Motor

    REMOVING AND CARRYING THE OUTBOARD MOTOR 1. Removing the outboard motor 3. Storing the outboard motor Stop the engine. Outboard motor should be stored in a Disconnect the fuel connector, vertical position. the remote control cables and the battery cords from the outboard Note motor.

  • Page 44: Trailering

    TRAILERING ������� ������� Do not go under outboard motor tilted When trailering the outboard motor up even if it is supported by support should be in a vertical (normal running) bar, or accidental fall of outboard motor position, fully down. Trailering in the could lead to severe personal injury.

  • Page 45: Adjustment

    ADJUSTMENT 1. Steering friction 2. Throttle grip MF, EF, EFT and EPT type MF, EF and EFT type The steering friction can be adjusted The turning force of the throttle grip in accordance with your preference can be adjusted with a throttle adjust by turning the steering adjust bolt.

  • Page 46: Remote Control Lever Load

    ADJUSTMENT When locking the shift lever in Notes Reverse (R) and Neutral (N), shift the reverse lock link from A to B The trim tab also acts as an anode to prevent electrolytic corrosion. position. Therefore do not paint or grease 4.

  • Page 47: Inspection And Maintenance

    ADJUSTMENT INSPECTION AND MAINTENANCE Care of your outboard motor EPA Emissions Regulations To keep your outboard motor in the EPA (United States Environmental best operating condition, it is very Protection Agency) has emission important that you perform daily and regulations regulating air pollution periodic maintenance as suggested from new outboard motors.

  • Page 48: Daily Inspection

    INSPECTION AND MAINTENANCE 1. Daily inspection Perform the following checks before ������� and after use. Do not use outboard motor if any abnormality is found during pre-operation check or it could result in severe damage to the motor or severe personal injury. Item Points to Check Remedy...
  • Page 49 INSPECTION AND MAINTENANCE Notes Maintaining engine oil If the engine oil is low, the life of the Consult with an authorized dealer engine will be shortened significantly. if the engine oil is milky color, or appears contaminated. Checking oil level Stop the engine and set it in a vertical position.
  • Page 50 INSPECTION AND MAINTENANCE Washing outboard motor Use flushing attachment. If outboard motor is used in salt Remove propeller (refer to Propeller water, brackish water or water with a Replacement). Remove the water high acidic level, use fresh water to plug from the motor, and screw in remove salt, chemicals or mud from the flushing attachment.
  • Page 51 INSPECTION AND MAINTENANCE ������� Replacing the propeller A worn-out or bent propeller will lower Do not hold propeller with hand(s) the motor's performance, and cause when loosening or tightening propeller engine trouble. nut. Put a piece of wood block between Before removing the propeller, remove propeller blade and anti-ventilation plate to hold propeller.
  • Page 52 INSPECTION AND MAINTENANCE Attach spark plug and tighten to Replacing the spark plugs specified torque. ������� Notes Do not reuse spark plug with damaged insulation, or sparks Spark plug torque : can leak through crack, potentially 18.0Nm(13.3ft-lb)(1.84kgf-m) leading to electric shock, explosion If a torque-wrench is not available and/or fire.
  • Page 53 INSPECTION AND MAINTENANCE Recommended oil Checking and Refilling Oil in the Use an automatic transmission Power Tilt. Check the oil level of the reservoir fluid or equivalent. tank as shown on the right while Recommended oils are as shown t h e t a n k i s k e p t i n a v e r t i c a l below.

  • Page 54: Periodic Inspection

    INSPECTION AND MAINTENANCE 2. Periodic inspection It is important to inspect and maintain your outboard motor regularly. At each interval on the chart below, be sure to perform the indicated servicing. Maintenance intervals should be determined according to the number of hours or number of months, whichever comes first.
  • Page 55 INSPECTION AND MAINTENANCE Notes Drain hole Your outboard motor should receive careful, and complete inspection at 300 hours. This is the best time for major maintenance procedures to be carried out. Replacing engine oil Engine oil mixed with dust or water U s e o n l y h i g h q u a l i t y 4 - s t r o k e will dramatically shorten the life of the engine oil to insure performance and...
  • Page 56 INSPECTION AND MAINTENANCE ������� Cleaning the fuel filters and the fuel tank You may be injured due to high engine Fuel filters are located inside the fuel temperatures if you fill engine oil just tank and engine. after stopping. Changing engine oil should be done after the engine has �������...
  • Page 57 INSPECTION AND MAINTENANCE Fuel filter (for fuel tank) Loosen the fuel pickup elbow shown at left, remove it and clean the fuel filter. Fuel Filter pick up elbow Fuel tank Water or dirt in the fuel tank will cause engine performance problems. Check and clean the tank at periodical inspection or after the outboard motor has been stored for a long period of...
  • Page 58 INSPECTION AND MAINTENANCE until oil flows out from upper plug Replacing gear oil hole. Oil plug (Upper) ������� Be sure that outboard motor is secured to transom or service stand, or accidental drop or fall of outboard motor could lead to severe personal injury. Be sure to lock outboard motor if it is tilted up, or accidental fall of outboard motor could lead to severe...

  • Page 59: Off-Season Storage

    INSPECTION AND MAINTENANCE 3. Off-season storage Change the gear oil in the gear Before you put your outboard motor case. in storage, it is a good opportunity to Apply grease to the propeller shaft. have it serviced and prepared by your Apply grease to all sliding parts, dealer.

  • Page 60: Pre-Season Check

    INSPECTION AND MAINTENANCE 4. Pre-season check 5. Motor submerged in water Check that the shift and throttle After taking your outboard motor out function properly. of the water, immediately take it to (Be sure to turn the propeller shaft your dealer. when checking the shift function The following are the emergency or else the shift linkage may be...

  • Page 61: Cold Weather Precautions

    INSPECTION AND MAINTENANCE 6. Cold weather precautions 7. Checking after striking underwater object If you moor your boat in cold weather S t r i k i n g t h e s e a b o t t o m o r a n at temperatures below 0˚C (32˚F), underwater object may severely there is the danger of water freezing...

  • Page 62: Troubleshooting

    TROUBLESHOOTING If you encounter a problem, consult the check list below to determine the cause and to take the proper action. An authorized dealer will always be happy to provide any assistance and information. Possible cause Empty fuel tank Incorrect connection of fuel system Air entering fuel line Deformed or damaged fuel hose Closed air vent on fuel tank...
  • Page 63 TROUBLESHOOTING Possible cause Spark plug other than specified Dirt, soot, etc. on spark plug Faulty oil pressure switch No Spark or weak spark Short circuit of engine stop switch Ignition timing incorrect Lock plate not fitted Disconnection of wire or loose ground connection Blown 20 Amp fuse in the starting circuit Not shifted to neutral position Weak battery or battery connections are loose or corroded...
  • Page 64 TROUBLESHOOTING Possible cause Low compression Carbon deposits in the combustion chamber Incorrect valve clearance Low oil pressure/level Low oil level Use of improper oil Oil deterioration Clogged oil strainer Faulty oil pump Incorrect adjustment of throttle link Insufficient cooling water flow, clogged or defective pump Faulty thermostat Cavitation or ventilation Incorrect propeller selection...

  • Page 65: Tool Kit And Spare Parts

    TOOL KIT AND SPARE PARTS The following a list of the tools and spare parts provided with the motor. Items Quantity Remark Tool bag Pliers Socket wrench 13 mm Socket wrench 16 mm (spark plug) Service tools Socket wrench handle Screwdrivers Cross-and straight-point Screwdriver handle...

  • Page 66: Optional Accessories

    OPTIONAL ACCESSORIES Selector Tachometer Genuine grease (250g) Tachometer with oil lamp (for EPT) Genuine gear oil (500ml) Touch-up paint (300ml) Propeller Genuine engine oil (450ml) High thrst propeller Flushing attachment...

  • Page 67: Propeller Table

    PROPELLER TABLE Use a genuine propeller. A propeller must be selected so that the engine rpm measured at wide open throttle while cruising is within the recommended range. 5,000 to 6,000 rpm Propeller Size (Diameter pitch) Propeller Mark No. of Brades inch Light boats Heavy boats...
  • Page 68 M E M O...
  • Page 69 M E M O...
  • Page 70 M E M O...
  • Page 72 TOKYO (03)3966-2951 E-mail : www.tohatsu.co.jp 9.8A3 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. 003-11082-5 0912NB...

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