Water Separator Inspection and Service

Engine damage or performance problems that result from using a fuel with percentages of ethanol or methanol greater than shown above are not covered under warranty.

If your outboard motor will be used on an infrequent or intermittent basis, please refer to the fuel section of the STORAGE chapter (p.103) for additional information regarding fuel deterioration.

SERVICING YOUR OUTBOARD MOTOR

Water Separator Inspection and Service

WATER SEPARATOR

Water separator is located near the engine cover latch on the boat side. Water accumulation in the water separator can cause loss of power or hard starting. Check the water separator periodically. Clean it or consult with an authorized TOHATSU outboard motor dealer for cleaning. 1.Remove the engine cover (p.77).

2.Remove the separator assembly. If it is difficult to remove the separator assembly by yourself, consult an authorized TOHATSU dealer.

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel. •Stop the engine and keep heat, sparks, and flame away. •Handle fuel only outdoors. •Wipe up spills immediately.

SERVICING YOUR OUTBOARD MOTOR

HOSE CLIPS (commercially available)

WATER SEPARATOR WATER SEPARATOR BRACKET WATER SEPARATOR HARNESS CLIP WATER LEVEL SENSOR 2 pin CONNECTOR

CLIP C

FUEL HOSES

3.Pinch the fuel hoses with hose clips to prevent fuel leakage. 4.Remove the suspension strap from the water separator bracket; then remove the strap from the separator assembly.

During removal of the separator assembly, take care not to damage the wire harness with the separator bracket. 5.Open the harness clip and remove the harness from clip C; then disconnect the water level sensor 2 pin connector.

6.Disconnect the fuel hoses from the water separator.

SUSPENSION STRAP HARNESS

BODY BAFFLE

PLATE O-RING (Replace)

SERVICING YOUR OUTBOARD MOTOR

•Assemble so the flat part on the back of the suspension is parallel to the water separator joint as shown below.

Assemble so the flat part of the suspension and the water separator joint are parallel to each other. POSITIONING BAND

HARNESS CLIP WATER LEVEL SENSOR 2 pin CONNECTOR

SCREW (3)

WATER SEPARATOR CUP SUSPENSION STRAP

7.Remove the three screws and separate the water separator cup from the body.

8.Thoroughly clean the water separator cup.

9.Reassemble the water separator in the reverse order of removal. Use a new O-ring.

TIGHTENING TORQUE: 3.1 lbf·ft (4.2 N·m, 0.43 kgf·m)

WATER SEPARATOR

FLAT PART ON BACK OF SUSPENSION JOINT HARNESS CLIP C POSITIONING BAND

10.Connect the water level sensor 2 pin connector. Install the harness to clip C and the harness clip.

Align the positioning bands on the harness with the end of clip C and the harness clip as shown above.

11.Reinstall the water separator in the reverse order of removal.