Distribute to: Sales div. Service div. Parts div. Accounting div. No.06-002 New Model Information The next generation of direct fuel injection outboard motor equipped with a 32 bit ECU (Engine Control Units) that commands the fuel control system to inject fuel of the most suitable amount at optimum moment to the operating conditions that vary momentarily according to information from sensors arranged on various areas of the engine. This product meats requirements of EPA emission regulations and the self-regulation by the Japan Boating Industry Association. This is the TLDI (Two stroke Low pressure Direct Injection) model that provides both linear acceleration responding directly to the throttle operation and ecological performance that makes the machine earth-friendly. Individual sensors During operations, the ECU controls the engine to achieve the highest possible efficiency according to information from six kinds of sensors. Idle noise reduction system Reduces the exhaust noise to offer more quiet and comfortable boating. 1 of 10
Specifications MD115 Model Unit MD115A Overall Length in.(mm) 31.5(800) Overall Width in.(mm) 19.5(495) Overall Height (L) in.(mm) 64.6(1,640) Overall Height (UL) in.(mm) 69.7(1,767) Transom Height (L) in.(mm) 20.4(517) Transom Height (UL) in.(mm) 25.4(644) Weight (L) lbs(kg) 393(178) Weight (UL) lbs(kg) 399(181) Engine Type Two-stroke gasoline engine with direct fuel injection Maximum Output HP(Kw)/rpm 115(84.6)/5500 Maximum Torque ft.lb(kgm)/rpm 119(16.5)/4500 Displacement CC(cu.in) 1,768(107.9) Bore Stroke in.(mm) 3.46 2.86 (88 72.7) Number of Cylinder 4 Max. RPM Range rpm 5,1505,850 Idling Speed (In neutral) rpm 700800900 Trolling Speed (In gear) rpm 700800900 Fuel Consumption l/hr 45 Starting System Intake System Scavenging System Exhaust System Lubrication System Cooling System Water Temp. Control Ignition System Ignition Timing Electric starter motor Reed valve 5-port loop charge Through hub Oil injection Water-cooling Thermostat (with pressure relief valve) Inductive Firing Order 1-3-2-4 Spark Plug Alternator ECU NGK : IZFR5J 12V-490W More than 0 C (32 F) 12V 100AH (CCA: 800A, MCA: 1000A) Battery 0 C (32 F) & Below 12V 120AH (CCA: 900A, MCA: 1100A) Trim Angle degree 8 24 Number of Trim Position 2 Maximum Tilt Angle degree 75 Maximum Thickness of Transom in.(mm) 1.222.75 (3170) Steering Angle degree 66 Clutch Gear Ratio Engine Oil Dog clutch (F-N-R) 2.01326) Genuine MD Platinum or Equivalent Engine Oil Capacity L 6.7 Recommended Fuel Unleaded regular gasoline Gear Oil Genuine gear oil or GL5, SAE #80 to #90 Capacity of Gear Oil fl.oz(ml) 30.4 (900) Warning System Over-revolution Protection rpm Approx. 6,000 Over Heat Protection rpm Approx. 3,000 Engine Oil Pressure Warning Indicator rpm Approx. 3,000 Optional Parts Optional Propeller Pitch 11, 13, 15, 16, 17, 19, 21 Specifications and descriptions are subject to change without notices. 2 of 10
Dimensions 634mm (25.0in) (kg/lbs) Model Dry Weight EPTOL 178 (393) EPITOUL 181 (399) (mm/in) A B C Transom L: 1640 (64.6) 517 (20.4) 970 (38.2) Transom UL: 1767 (69.7) 644 (25.4) 1084 (42.7) 3 of 10
Warning Indicator Definition TableWhile Operating Engine Warning Indicators Buzzer Sounding ESG Speed Control (*1) Fault Description Reference Remedy Indicator A Indicator B Indicator C Continuous High speed ESG Engine over-rev. Approx. 6,000 r/min Readjust propeller and outboard engine mounting height and trim. Intermittent (3 beeps for every 2 minutes) Flashing - Low oil level Approx. 1400mL or less Replenish engine oil. Continuous Flashing Low speed ESG Cooling water temp. high 85 Continuous Flashing Forced idling Cooling water temp. abnormally high temp. 90 Continuous Flashing - Air compressor cooling water temp. high 90 Continuous Flashing Low speed ESG Air compressor cooling water temp. abnormally high 100 Refer to troubleshooting. 4 of 10 - Flashing Low speed ESG Battery voltage abnormally low Approx. or less - Flashing - Battery voltage low Approx. or less - Flashing Flashing Flashing Low speed ESG Battery voltage high Approx. or more - Flashing Flashing Flashing Engine stop Battery voltage abnormally high Approx. or more - Flashing Flashing Flashing - Faulty (*2)Idle position - Flashing Flashing Flashing Forced idling Faulty TPS1 and TPS2 - Flashing Flashing Flashing Low speed ESG Faulty TPS1 or TPS2 Refer to Fault Indication Table. - Flashing Flashing Flashing Forced idling Faulty power supply TPS1 and TPS2 - Flashing Flashing Flashing Low speed ESG Faulty power supply TPS1 or TPS2 *1. Speed control High speed ESG - Flashing Flashing Flashing - Faulty air injector Regulated to approx., rpm. - Flashing Flashing Flashing - Faulty fuel injector Low speed ESG - Flashing Flashing Flashing - Faulty ignition coil Regulated to approx., rpm. Forced idling Regulated to idling speed. - Flashing Flashing Flashing - Faulty (*3) *2. Throttle position sensor - Flashing Flashing Flashing - Faulty (*4) - Flashing Flashing Flashing - Faulty temp. sensor Engine or air compressor *3. Fuel feed pump (electric) - Flashing Flashing Flashing - Faulty MAP sensor *4. Crank position sensor - Flashing Flashing Flashing - Faulty MAT sensor - Flashing Flashing Flashing - Faulty main power relay Intermittent (3 beeps for every 2 minutes) Flashing Note: Items marked with are additions of M115A. Flashing Flashing Forced idling Faulty oil pump
Engine Operating Hours Table (self-diagnosing mode 2) Engine Operating Hours Tachometer Reading (h) (r/min) Indicator A Indicator B Indicator C 0 1 1,000 1 2 2,000 2 3 3,000 3 4 4,000 4 5 5,000 5 6 6,000 6 7 7,000 7 8 800 On 8 9 900 On 9 10 1,000 On 10 20 2,000 On 20 30 3,000 On 30 40 4,000 On 40 50 5,000 On 50 60 6,000 On 60 70 7,000 On 70 80 800 On On 80 90 900 On On 90 100 1,000 On On 100 200 2,000 On On 200 300 3,000 On On 300 400 4,000 On On 400 500 5,000 On On 500 600 6,000 On On 600 700 7,000 On On 700 800 800 On On On 800 900 900 On On On 900 1000 1,000 On On On 1000 2000 2,000 On On On 2000 3000 3,000 On On On 5 of 10
Fault Indication Table (self-diagnosing mode 3 Fault Log Malfunction / Failure indication Fault Fault Log (Yes) Description of Problem Remedial Measures and Added Notes Tachometer (r/min) Indicator A Indicator B Indicator C 0 Off No malfunction or failure Off Off 0 0 On Flashing Battery voltage high Battery voltage abnormally high fault. fault. Refer to troubleshooting. 1,000 Off Faulty #1 air injector 1,000 On Faulty #1 fuel injector 1,000 Flashing Faulty #1 ignition coil 2,000 Off Faulty #2 air injector 2,000 On Faulty #2 fuel injector 2,000 Flashing Faulty #2 ignition coil 3,000 Off Faulty #3 air injector 3,000 On Faulty #3 fuel injector Off Stays off even when line is severed or component is faulty. Refer to *1. Refer to *2. Replace components, or check the wiring and connections for abnormalities and repair as necessary. *1. In the case of injector and ignition coil faults, indicator B does not illuminate when self-diagnosing modes are enabled while the engine is off. This is to determine whether operation is under ECU control. *2. Indicator C illuminates to indicate that there is a severed line or fault in a component. Remedy; Delete current fault log(using Mode 4), operate the engine(or simply turn it over for 5 seconds or longer), and run the self-diagnosing function again to determine the type of fault. In instances when Indicator C again illuminates for the same malfunction or failure take remedial measures. In case of injector problems Replace with new injector. If the fault remains, check the wiring. 6 of 10 3,000 Flashing Faulty #3 ignition coil 4,000 Off Faulty #4 air injector 4,000 On Faulty #4 fuel injector 4,000 Flashing Faulty #4 ignition coil 650 Off Low oil level On indicates low oil level. On indicates low oil level history. In case of ignition coil problems If only one ignition coil is indicated as faulty replace with a new coil. If the fault remains, check the wiring. If all three ignition coils are indicated as faulty it means that there could be a short in the wiring or in one of the coils. Replenish engine oil. *Fault indicator remaining illuminated after engine oil has been replenished indicates a severed or shorted line or faulty component. 650 650 On Flashing Battery voltage low Battery voltage abnormally low On indicates battery voltage low. On indicates low battery voltage history. Refer to troubleshooting. 4,500 Flashing Faulty oil pump Replace components or check wiring and connections for abnormalities and repair as necessary. Replace components or check wiring and connections for abnormalities and repair as necessary. fault. fault history. 5,000 Off Faulty *3 *When engine speed fluctuation is great a fault may be indicated even if there is no fault or abnormality with components or wiring. 5,000 On #1 TPS(*4) idling position error 5,000 Flashing #2 TPS idling position error On indicates incorrect TPS initial settings. On indicates incorrect TPS initial settings history. Refer to the procedure for restoring TPS initial values. 5,500 Off Faulty #1 5,500 On #1 TPS power supply high 5,500 Flashing #1 TPS power supply low 6,000 Off Faulty #2 6,000 On #2 TPS power supply high fault. fault history. Replace component or check wiring and connections for abnormalities and repair as necessary. 6,000 Flashing #2 TPS power supply low 6,500 Off Faulty engine water temp. sensor 3,500 Off Faulty air compressor water temp. sensor
Malfunction / Failure indication Fault Fault Log Fault Log (Yes) Description of Problem Remedial Measures and Added Notes Tachometer (r/min) Indicator A Indicator B Indicator C 6,500 On Cooling water temp. high 6,500 Flashing Cooling water temp. abnormally high 7,000 On Air compressor cooling water temp. high On indicates cooling water temperature is high. On indicates high cooling water temperature history. Refer to troubleshooting. 7,000 Flashing Air compressor cooling water temp. abnormally high 7,000 Off Faulty *5 Off Off Refer to troubleshooting. 4,500 Off Faulty MAP sensor 4,500 Off Faulty MAT sensor fault. fault history. Refer to troubleshooting. 2,500 Off Faulty main power relay 7 of 10
<Shipment of Product> The shipment of 115A does not include the propeller, remote control box and pre-rigging kit. It is necessary to select a pre-rigging kit described below depending on the remote control box to be used. These items are available from Tohatsu Parts Center by using the same process for ordering other parts. 1 Propeller No.17 No change No.10 No.9 (Color: Black) No.11 (Color: No change) No.8 <Notes> The newly available propeller is dedicated only to MD115A. For models M60C/70C, MD70B/90B, M90A or M120A2/140A2, use a propeller ass y with the part number 3N4W series(example: 3N4W64536-1) or a propeller hub kit (3Y9-64238-0). No. Part Name Part Number Q'ty 1 Propeller assy 11 3T1W64523-0 1 2 Propeller assy 13 3T1W64527-0 1 3 Propeller assy 15 3T1W64532-0 1 4 Propeller assy 16 3T1W64534-0 1 5 Propeller assy 17 3T1W64536-0 1 6 Propeller assy 19 3T1W64541-0 1 7 Propeller assy 21 3T1W64545-0 1 8 Propeller hub kit 3T1-64238-0 1 9 Drive sleeve assy Not available 1 10 Drive sleeve adapter Not available 1 11 Forward thrust washer 3E0-64235-0no change 1 8 of 10
2 Remote control boxes Top Mount and Flush Mount Remote Controls No. Part Number Part Name 1 3U1-84490-0 Single top mount control 2 3U1-84540-0 Twin top mount control 3 3U1-84600-0 Flush mount control The installation of the above remote control requires the use of the following pre-rigging kit. For twin top mount control, two(2) sets of the pre-rigging kit are needed. Note: The pre-rigging kit does not include a control box. No. Q'ty Part Number Part Name Remarks 3Z5-84550-3 Pre-rigging kit For top mount and flush mount remote control box 1 1 3Y9-84560-1 Rigging cord kit Outboard motor to switch, remote control box and meters 1-1 1 3Y9-76250-0 Main switch panel assy 1-1-1 1 3Y9-76201-0 Main switch panel 1-1-2 1 3Y9-76020-0 Main switch assy 1-1-3 1 3Y9-06830-0 Stop switch assy 1-2 1 3Y9-76171-0 Overheat warning buzzer 1-3 1 3Y9-76115-0 Cord assy Outboard motor to switch, remote control box and meters 1-4 1 3Y7-76119-1 Cord assy Remote control box to main harness 2 1 3Z5-72640-1 Tachometer with oil lamp 3 1 3T5-72537-0 Meter lead wire 4 1 3E0-72571-0 Trim meter assy Meters to main harness 5 1 3F3-72573-1 Extension cord (trim sensor) Trim meter to trim sender 6 1 3B7-70200-3 Primer bulb assy 7 1 353-72548-0 Assist cord (black) Meters to meter lead wire, grounding wire for meters 9 of 10
Side Mount Remote Control For the installation of the side mount remote control box, it is necessary to use the following pre-rigging kit. No. Q 'ty Part Number Part Name Remarks kit includes a side mount 3Y7Q84550-3 Pre-rigging kit For Tohatsu side mount remote control box 1 1 3T5Q84500-1 Remote control head ass y 2 1 3Z5-72640-1 Tachometer with oil lamp 3 1 3T5-72537-0 Meter lead wire 4 1 3E0-72571-0 Trim meter assy Meters to main harness 5 1 3F3-72573-1 Extension cord (trim sensor) Trim meter to trim sender 6 1 3B7-70200-3 Primer bulb assy Note: A pre-rigging remote control box. 7 1 353-72548-0 Assist cord (black) Meters to meter lead wire, grounding wire for meters 3 Optional parts No. Part Number Part Name Remarks 1 3Y9-76251-0 Lamp panel ass y Warning lamp (To be used for tachometers made by other than Tohatsu.) 2 3U1-84540-0 Lead wire Power supply cord for twin remote control box 3 3U1-02230-0 Fuel filter assy UNIKAS, OB-30 10 of 10