TOHATSU F40 User manual

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

Tillerhandle_F4050E_160316.indd 1 16.3.16 5:57:46 PM

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.

Tillerhandle_F4050E_160316.indd 2 16.3.16 5:57:50 PM

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

S:740 L:873 UL:987

Tillerhandle_F4050E_160316.indd 3 16.3.16 5:57:51 PM

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.

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]

Tillerhandle_F4050E_160316.indd 4 16.3.16 5:57:57 PM

Installation Maual 2016

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.

Tillerhandle_F4050E_160316.indd 5 16.3.16 5:57:59 PM

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.

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.

Tillerhandle_F4050E_160316.indd 6 16.3.16 5:58:00 PM

Installation Maual 2016

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.

Tillerhandle_F4050E_160316.indd 7 16.3.16 5:58:01 PM

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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Friction Lever Installation

1. Install following parts, following steps.

· bolt 1

Tillerhandle_F4050E_160316.indd 8 16.3.16 5:58:03 PM

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.

OFF

START

PUSH TO IDLE CHANGE

Tillerhandle_F4050E_160316.indd 9 16.3.16 5:58:04 PM

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

YYellow

PPink

Lg LightGreen

Sb Sky Blue

YRed/Yellow

RGreen/Red

RYellow/Red

*"/"meanscordswithstripedcolors.

Sb Sb

Br Br

R/Y

G/R

Y/R

G/R

Y/R

R/Y

Lg Y/R

G/R

Wiring Diagram

Contact

TOHATSU CORPORATION

Adress: 5-4, Azusawa 3-Chome, Itabashi-ku, Tokyo, Japan

Phone: +81-3-3966-3117

be reproduced or transmitted in any from or by any means without the express written

permission of Tohatsu Corporation.

Tillerhandle_F4050E_160316.indd 10 16.3.16 5:58:05 PM

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