TOHATSU MES 4C, Owner'S Manual

Page 1: ...59 7 1012NB Printed in Japan TOHATSU CORPORATION Address 5 4 3 chome Azusawa Itabashi ku TOKYO 174 0051 JAPAN Phone TOKYO 03 3966 3117 FAX TOKYO 03 3966 2951 URL www tohatsu co jp 4C 5C 6C MFS OWNER S MANUAL TOHATSU_4C 5C 6C_E_cover indd 1 11 01 21 17 49 ...

Page 2: ...y 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 TOHATSU_4C 5C 6C_E_cover indd 2 11 01 21 17 49 ...

Page 3: ...NT PERMITTED BY APPLICABLE LAW YOUR OUTBOARD MOTOR WILL NOT BE COVERED BY THE APPLICABLE LIMITED WARRANTY IF THIS PROCEDURE IS NOT FOLLOWED 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 whi...

Page 4: ...nt 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 s...

Page 5: ... 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 TO...

Page 6: ...TOHATSU_4C 5C 6C_E_body_110214 indd 6 11 02 21 18 33 ...

Page 7: ... 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 INDEX GENERAL SAFETY INFORMATION TOHATSU_4C 5C 6C_E_body_110214 indd 7 11 02 21 18 33 ...

Page 8: ...ailure to observe will result in severe personal injury or death and possibly property damage DANGER 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 CAUTION WARNING Failure to observe could result in severe personal injury or death or pr...

Page 9: ...is 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 instructio...

Page 10: ... Gear rpm 1 300 Engine Type 4 Stroke Number of Cylinder 1 Bore Stroke mm in 59 45 2 32 1 77 Piston Displacement mL Cu in 123 7 5 Exhaust System Through hub exhaust Cooling System Water cooling Engine Lubrication Trochoid pump Startring System Manual Starter Ignition System Flywheel Magneto C D ignition Spark Plug NGK DCPR6E Trim Position 6 Engine Oil API SF SG SH or SJ FCW 10W 30 40 Approx 450 15 ...

Page 11: ...8 19 20 21 22 23 24 25 26 Clamp Bracket Clamp Screw Throttle Grip Shift Lever Starter Handle Choke Knob Stop Switch Fuel Connector Warning Lamp Air Vent Screw Fuel Connector Fuel Cock Primer Bulb 27 28 29 30 31 32 33 34 Fuel Tank Fuel Pick up Elbow Fuel Connector Air Vent Screw Fuel Tank Cap Engine Oil Filter Cap Spark Plug Engine Oil Drain Screw 11 1 2 3 4 5 6 7 8 9 10 11 12 13 4C 5C 6C NAMES OF ...

Page 12: ...til it has been securely mounted on the boat in accordance with the instructions below 1 Mounting the outboard motor on boat INSTALLATION Boat Transom Center of 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 of water surface on the driveshaft housing If the water surface is near the bottom cowling...

Page 13: ...out of control or causing 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 delivered or their equivalents in terms of size material quality and strength Tighten fasteners to the specified torque 30 Nm 3 0kgf 13ft lb T...

Page 14: ...operating difficulties wear of and damages to engine parts and deterioration of chemical parts which may lead to shortening of your outboard motor s life CAUTION 1 Recommended gasoline types Consult an authorized dealer for details on handling 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...

Page 15: ...acity 25 liters 6 6 U S gal for 30 40 50 Fuel Tank When using a fixed fuel tank in place of genuine fuel tank it is recommended to select a one with a structure facilitating interior cleaning Use only high quality 4 stroke engine oil to insure performance and prolonged engine life Use NMMA FC W certified 4 stroke WARNING Do not fill the fuel tank over capacity The rise of gasoline temperature may ...

Page 16: ...ice life 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 CAUTION PRE OPERATING PREPARATIONS Do not operate the outboard motor in closed area or area with no forced ventilation Exhaust gas emitted by...

Page 17: ...el is within the appropriate level Consult with your dealer ESG is a device to prevent over revolution of the engine more than approximately 6 250 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 Slipping propeller rubber Making sharp turns at high speeds 17 1 2 3 4 5 6 7 8 9 10 11 12 13 PRE OPERATING...

Page 18: ...o separate tank side Squeeze primer bulb until it becomes stiff to feed fuel to carburetor separate tank 18 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Before starting 1 Starting Note The engine will not start unless the switch lock has been properly connected into the emergency stop switch ENGINE OPERATION Fuel tank side Engine side WARNING In case engine starts in gear do not start cruising Stop engine imm...

Page 19: ... gear do not use it Contact an authorized dealer CAUTION 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 R N F Shift Lever Note If engine does not start with 4 or 5 times starting operation push the knob back and restart...

Page 20: ...knob back slowly then return the grip to SLOW position and run the engine to warm up for several minutes 20 14 13 12 11 10 9 8 7 6 5 4 3 2 1 ENGINE OPERATION Be careful that your clothes or other items do not get caught in the rotating engine parts To prevent accident and injury do not re attach the recoil starter after the engine has been started using the emergency starter rope Be sure to put th...

Page 21: ...to check that cooling water is coming out of the cooling water check port during warm up 2 Warming up the engine If the engine is operated without water discharging from the check port the engine may over heat CAUTION Clutch in In gear Clutch off Out of gear 1 100rpm 1 300rpm 4 5 Wide open throttle rpm range 6 4 500 5 500rpm 5 000 6 000rpm Coolong water check port Be sure to stop engine immediatel...

Page 22: ...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 WARNING Attach other end of emergency stop switch tether to the operator s clothing or arm and keep it attached during cruising Do not attach the tether to a part of clothing that can be torn easily when pulled Arrange the tether so...

Page 23: ...ation of parts In such case replace gear oil earlier than the period specified Be sure to warm up engine well before starting cruise Operating cold engine may cause damage to your motor CAUTION 4 Stopping Stop Switch Lock Stop Switch Hock WARNING Do not shift into Reverse during planing or control will be lost leading to serious personal injury boat may swamp and or hull may be damaged Do not shif...

Page 24: ...the bow of the boat is below horizontal 24 14 13 12 11 10 9 8 7 6 5 4 3 2 1 ENGINE OPERATION 5 Trim angle Perpendicular to the water surface WARNING Excessive trim up or down may lead to unstable boat operation potentially causing the steering difficulty that leads to accident during cruising Do not cruise at high speed if improper trim position is suspected Stop the boat and readjust trim angle b...

Page 25: ...justing trim angle WARNING Excessive trim up or down may lead to unstable boat operation potentially causing the steering difficulty that leads to accident during cruising Do not cruise at high speed if improper trim position is suspected Stop the boat and readjust trim angle before continuing cruise Note Stop the engine before tilting up 6 Tilt up tilt down and shallow water operation WARNING Whe...

Page 26: ...tboard motor body and clamp bracket when adjusting trim angle to prevent injury in case the outboard motor body falls When tilting up outboard motor with fuel joint for over a few minutes be sure to disconnect fuel hose or close fuel cock or fuel may leak potentially catching fire Note Slow down to trolling speed and shift into neutral before setting outboard motor to shallow water drive position ...

Page 27: ...oard motor against sea bottom or propeller may be pushed out of water resulting in loss of control Tilt Stopper Tilt Lever WARNING Do not tilt up or down outboard motor when swimmer s or passenger is near to prevent them from being caught between outboard motor body and clamp bracket in case the outboard motor body falls WARNING When tilting up outboard motor with fuel joint for over a few minutes...

Page 28: ...4 inches if traveling to avoid oil spillage 2 Carrying the outboard motor 3 Storing the outboard motor REMOVING AND CARRYING THE OUTBOARD MOTOR Do not carry or store outboard motor in any of positions described below Otherwise engine damage or property damage could result from leaking oil CAUTION WARNING Close air vent screw of fuel tank and fuel cock before carrying or storing outboard motor and ...

Page 29: ...he outboard motor boat etc If trailering with outboard fully down is not available the gear case skeg is too close to the road in a vertical position fix the outboard motor securely using a device like a transom saver bar in the tilted position CAUTION TRAILERING WARNING Do not go under outboard motor tilted up even if it is supported by support bar or accidental fall of outboard motor could lead ...

Page 30: ...avier Lighter Heavier Lighter Throttle Adjustment Screw Note The steering adjustment bolt is used to adjust the friction load of the steering but not to fix the steering Excess tightening of the adjustment bolt may cause damage to the swivel bracket WARNING Do not overtighten the throttle grip or remote control tensioner or it could result in difficulty of movement resulting in the loss of control...

Page 31: ...ed by any marine SI Spark Ignition engine repair establishment or individual 31 1 2 3 4 5 6 7 8 9 10 11 12 13 Your personal safety and that of your passengers depends on how well you maintain your outboard motor Carefully observe all of the inspection and maintenance procedures described in this section The maintenance intervals shown in the checklist apply to an outboard motor in normal use If yo...

Page 32: ...coil Starter Check the rope for wear and chafing Check the ratchet engagement Replace Correct or replace Clutch and Propeller System Check that clutch engages correctly when operating the shift lever Visually Check propeller for bent or damaged blades Check the propeller nut is tightened and the split pin is present Adjust Replace Installation of Motor Check all the bolts attaching the motor to th...

Page 33: ... milky color or appears contaminated Oil Filler Cap Dipstick Lower Level 350 mL Upper Level 450 mL Do not add engine oil of brand and grade other than existing one In case engine oil of other brand or grade is added drain all oil and ask dealer for treatment In case other than engine oil such as gasoline is put in the oil chamber empty the chamber and ask dealer for treatment When replenishing eng...

Page 34: ...level use fresh water to remove salt chemicals or mud from exterior and cooling water passage after every cruising or before storing outboard motor for long time Before flushing remove the propeller and the forward thrust holder 34 14 13 12 11 10 9 8 7 6 5 4 3 2 1 WARNING Never start or operate the engine indoors or in any space which is not well ventilated Exhaust gas contains carbon monoxide a c...

Page 35: ...it pin Nut WARNING Do not hold propeller with hand s when loosening or tightening propeller nut Put a piece of wood block between propeller blade and anti ventilation plate to hold propeller WARNING Do not begin propeller removal and installation procedure with spark plug caps attached shift in forward or reverse main switch at other than OFF engine stop cord attached to the switch and starter key...

Page 36: ... plug torque 18 0Nm 13 3ft lb 1 84kgf m If a torque wrench is not available when you are fitting a spark plug a good estimate of the correct torque is 1 4 to 1 2 a turn past finger tight Have the spark plug adjusted to the correct torque as soon as possible with a torque wrench Notes When inspecting the plug always clean the gasket surface and use a new gasket Wipe off any dirt from the threads an...

Page 37: ...Replace if necessary Fuel tank Clean Ignition Spark plug Check gaps Remove carbon deposits or Replace if necessary 0 8 0 9mm 0 031 0 035in Ignition timing Check timing Starting System Starter rope Check for wear or chafing Engine Engine oil Replace if necessary Valve Clearance Check adjust Thermostat Check and Replace if necessary Lower Unit Propeller Check for bent blades damage wear Gear oil Rep...

Page 38: ...e API rating of SF SG SH or SJ Select the appropriate viscosity based on atmospheric temperature from the chart below You can also use NMMA FC W certified 4 stroke outboard oil below 10W 30 is recommended for use in all temperature 25W 40 may be used at temperatures above 4 C 40 F 38 14 13 12 11 10 9 8 7 6 5 4 3 2 1 INSPECTION AND MAINTENANCE Notes Your outboard motor should receive careful and co...

Page 39: ... of oil gauge drain oil to level lower than upper limit Be sure that outboard motor is in upright and level position when checking or changing oil Stop engine immediately if low oil pressure warning lamp is lit or oil leak is found or engine could be severely damaged Consult dealer CAUTION WARNING Gasoline and its vapors are very flammable and can be explosive Do not start this procedure while eng...

Page 40: ...l with gear oil by squeezing the oil tube Fuel pick up elbow Filter INSPECTION AND MAINTENANCE Oil plug hole Uper Oil plug Lower WARNING 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 person...

Page 41: ... is kept in the carbruretor for a long time gum and varnish will develop causing the float valve to stick restricting the fuel flow Remove the spark plugs and spray storage oil available from an authorized dealer into the combustion chamber through the spark plug holes while slowly turning the motor over using the recoil starter Change the engine oil 41 1 2 3 4 5 6 7 8 9 10 11 12 13 INSPECTION AND...

Page 42: ...use cloth to remove fuel remaining in the cowl and dispose of it in accordance with local fire prevention and environment protection regulations Notes The following steps must be taken when first using the engine after winter storage Fill the fuel tank completely with 12 liters Warm up the engine for 3 minutes in the NEUTRAL position Run the engine for 5 minutes at the slowest speed Run the engine...

Page 43: ... after running a short period to get all moisture completely out of the crankcase Inject a sufficient amount of engine oil through the spark plug holes Pull the recoil starter several times to circulate the oil throughout the outboard motor If you moor your boat in cold weather at temperatures below 0 C 32 F there is the danger of water freezing in the cooling water pump which may damage the pump ...

Page 44: ...ler or propeller shaft upper and lower mount rubber bolts and or mount bracket bolts Ask an authorized dealer to tighten any loose bolts and nuts and to replace damaged parts Damage to mount rubber the tilt stopper thrust rod gears and clutch and or propeller Ask an authorized dealer to replace damaged or defective parts 44 14 13 12 11 10 9 8 7 6 5 4 3 2 1 INSPECTION AND MAINTENANCE 7 Checking aft...

Page 45: ...Poor idling Poor acceleration Engine speed abnormally high Engine speed abnormally low Boat speed low Overheating of engine Warning lamp ON Possible cause FUEL SYSTEM Empty fuel tank Incorrect connection of fuel system Air entering fuel line Deformed or damaged fuel hose Closed air vent on fuel tank Clogged fuel filter fuel pump or carburetor Use of improper engine oil Use of improper gasoline Exc...

Page 46: ...y low Boat speed low Overheating of engine Warning lamp ON Possible cause ELECTRICAL SYSTEM Spark plug other than specified Dirt soot etc on spark plug 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 TROUBLESHOOTING TOHATSU_4C 5C 6C_E_body_110214 indd 46 11 02 21 18 34 ...

Page 47: ...in the combustion chamber Incorrect valve clearance Low oil pressure level ENGINE OIL SYSTEM Low oil level Use of improper oil Oil deterioration Clogged oil strainer Faulty oil pump OTHERS Incorrect adjustment of throttle link Insufficient cooling water flow clogged or defective pump Faulty thermostat Cavitation or ventilation Incorrect propeller selection Damaged or bent propeller Improper thrust...

Page 48: ...ark Service tools Tool bag Pliers Socket wrench Socket wrench Socket wrench handle Screwdrivers Screwdriver handle 1 1 1 1 1 1 1 10 13 mm 16 mm Cross and straight point Spare parts Starter rope Spark plug Split pin 1 1 1 1 000 mm NGK DCPR6E Parts Packaged with Engine Fuel tank Primer bulb 1 1 set 12L TOHATSU_4C 5C 6C_E_body_110214 indd 48 11 02 21 18 34 ...

Page 49: ...Genuine gear oil 500ml Touch up paint 300ml Genuine engine oil 450ml Fuel Tank Primer Bulb Ass y 12L Propeller Remoto control box Various kinds of fitting parts are available Please consult with your dealer Fuel filter kit TOHATSU_4C 5C 6C_E_body_110214 indd 49 11 02 21 18 34 ...

Page 50: ...rpm 6 5 000 to 6 000 rpm S Short shaft L Long shaft UL Extra long shaft Sail Pro 50 14 13 12 11 10 9 8 7 6 5 4 3 2 1 PROPELLER TABLE Propeller Mark Propeller Size Diameter pitch Standard propeller on the model inch mm 4 5 6 Light boats Heavy boats 9 7 9 9 0 200 229 8 7 8 8 0 198 203 S L UL S L 7 7 8 7 0 198 178 S L UL UL 6 7 9 6 0 200 152 TOHATSU_4C 5C 6C_E_body_110214 indd 50 11 02 21 18 34 ...

Page 51: ...y 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 TOHATSU_4C 5C 6C_E_cover indd 2 11 01 21 17 49 ...

Page 52: ...59 7 1012NB Printed in Japan TOHATSU CORPORATION Address 5 4 3 chome Azusawa Itabashi ku TOKYO 174 0051 JAPAN Phone TOKYO 03 3966 3117 FAX TOKYO 03 3966 2951 URL www tohatsu co jp 4C 5C 6C MFS OWNER S MANUAL TOHATSU_4C 5C 6C_E_cover indd 1 11 01 21 17 49 ...