Owner’s Manual
Model Numbers:
P/N 25153
Date 05-19-01
TOB-120,TOB-300
OUTBOARD MOTORS
TOB-120
TOB-300
Supplier To The Outdoor Power Equipment Industry
ISM, Inc. • 1028 4th Street SW • Auburn, WA 98001 • Phone: (253) 333-1200 • Fax: (253) 333-1212
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TOB-120,TOB-300
Owner’s Manual
Instructions contained in this manual apply to models listed on this page. Use the instructions that
apply to your unit.
Models
Model………… TOB 120 Outboard Motor
Model………… TOB 300 Outboard Motor
Specific Model Number and Serial Number of your equipment are on a label on the unit. Record
numbers below and use them whenever parts or service are required.
Model Number -
Serial Number -
____________________________
____________________________
Engine Serial Number - ____________________________
Safety Precaution -
____________________________
Safety Precautions
Read and understand this Owner's Manual before operating this unit. Be thoroughly familiar with
controls and proper use of equipment. Know how to stop unit quickly in an emergency.
This Outboard Motor is a quality marine product designed to give years of dependable service when
operated and maintained properly. If rotating propeller comes in contact with your body, it will cause
severe personnel injury. If blade comes in contact with submerged hard objects, it may damage
blade. Be aware of sudden lifting of motor leg and propeller out of the water which may occur if an
underwater object is struck.
Understand and follow each Danger, Warning, Caution and instruction decals installed on equipment
or described in this manual.
Use only replacement parts designed for this unit.
See your Tanaka Dealer for a complete list. Although some unauthorized parts may appear to be
adaptable, their use may be extremely dangerous and could cause serious personal injury. This is
especially true of propellers which may be of poor construction or improperly balanced.
NEVER allow children to operate or play with unit. DO NOT allow adults to operate unit without
proper instructions. Anyone using this unit must understand the information in this manual.
Safe operation of this equipment requires complete and unimpaired attention at all times. DO NOT
operate unit if fatigued, during or after consumption of medication, drugs or alcohol.
When transporting unit in a vehicle, secure it to prevent it from sliding or tipping over which could
cause damage to your unit or spill fuel.
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TOB-120,TOB-300
Owner’s Manual
Safety Precautions cont.
Preparation
NEVER allow smoking materials, sparks or flame
(match, pilot light, etc.) near unit or gasoline
container.
Thoroughly inspect Outboard Motor for damage,
chipped propellers, fuel leaks, etc. before operating
this unit.
Check fuel supply before starting motor. Always
start boating trips with a full tank.
NEVER attempt to make any adjustments to unit
while motor is running (except where specifically
recommended).
DO NOT fill fuel tank indoors, when motor is
running or while motor is still hot. Wipe off any
spilled gasoline, allow vapors to dissipate and move
fuel container 10 feet (3m) away from unit before
starting motor.
Gasoline is highly flammable and its vapors are
explosive. Handle with care. Use an approved
(RED) gasoline container.
Operation
Keep equipment in good condition. Keep all guards
and shields in place and safety devices operating
properly.
Never allow swimmers or waders near unit while it
is in operation. The operator is responsible for the
safety of swimmers and boaters in the area.
Be sure that Throttle Lever stops motor when
moved to stop position and Lever moves freely. On
units equipped with Stop button, be sure button
stops unit.
After mounting motor on transom, set proper
motor trim according to size and weight of the
boat. See Tilt
Adjustment in Operation section of this manual.
Exhaust fumes contain carbon monoxide, an
odorless and deadly gas. DO NOT run motor in
enclosed or poorly ventilated areas.
Move Throttle Lever to stop position to stop
propeller. Always keep a fire extinguisher in the
boat along with life vests and other U. S. Coast
Guard approved safety equipment.
Before starting, make sure unit is properly secured
to boat transom using clamp stud handles. Be sure
a safety chain, from unit to boat, is installed. Check
clamp handles for tightness periodically.
Before attempting to make any adjustment,
repairs, inspections or cleaning unit, stop motor,
wait for moving parts to stop, allow unit to cool
then remove wire from spark plug .
Always carry a spare propeller, shear pins, hair
pins, spark plug and necessary repair tools such as
pliers, screwdriver, and wrenches.
If equipment vibrates abnormally during operation,
stop motor at once, wait for moving parts to stop,
and remove wire from spark plug. Abnormal
vibration is a warning of trouble. Repair any
damage before restarting unit. (See your Tanaka
Dealer.)
When starting unit, be sure propeller is clear of all
objects because when motor is started, throttle
may be set high enough to rotate the propeller.
After motor is started and idling smoothly, propeller
must not rotate. DO NOT operate unit if propeller
rotates when motor is idling.
After striking a submerged object, stop motor, wait
for moving parts to stop, then remove wire from
spark plug. Thoroughly inspect unit for any
damage. Repair damage before restarting and
operating unit.
DO NOT put hands or other body parts near
rotating parts.
Maintain a firm hold on the twist grip at all times to
help keep control of the unit.
Before shutting motor off, after operating under full
load for an extended period, lower motor speed
and allow it to idle for a few minutes so that motor
parts can cool evenly.
Operate equipment only when there is good
visibility and light.
In the event of an emergency, stop the motor by
moving Choke Lever to full choke position.
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TOB-120,TOB-300
Owner’s Manual
Safety Precautions cont.
Boating, Trailering and Auxiliary Use Tips
When trailering this unit, secure motor in an upright (vertical) position against boat transom. Do not
trailer with unit tilted up. If unit must be transported while tilted up, place a suitable brace, such as a
2 x 4, between motor bracket and motor leg. Tie down motor leg against brace to prevent damage to
motor leg.
When transporting unit in a vehicle, secure it to prevent turnover which could result in spilled fuel or
damage to unit.
To prevent fuel leakage from the carburetor when unit is tilted, close vent screw on fuel tank, turn
off fuel shut off valve, and allow unit to run at idle until it stops.
Take all possible precautions when leaving unit unattended. Remove and keep wire away from spark
plug to prevent accidental starting or unauthorized use.
When loading boat, distribute weight evenly to prevent tipping. Keep heavy loads low in the boat.
Do not stand up in a small boat. Standing, bow riding, seat back and gunwale riding can be
dangerous.
When loading or launching a boat on a trailer, tilt motor up to prevent propeller from striking ramp or
underwater objects.
An auxiliary adjustable position motor bracket is recommended when using unit as auxiliary power for
watercraft.
Maintenance and Storage
Periodically check that Throttle Lever stops motor when moved to stop position and Lever moves
freely.
Periodically check operation of propeller clutch brake. Propeller should stop almost immediately when
throttle is fully released. DO NOT operate unit if brake does not operate properly. Have unit serviced
by your Tanaka dealer before operating.
Discard propellers that are broken or damaged in any way. Replace only with Tanaka original
equipment replacement parts for safety.
Keep all nuts, bolts and screws tight and be sure equipment is in safe working condition. Check all
hardware at regular intervals.
NEVER store unit with gasoline in tank inside a building where fumes may reach an open flame or
spark. Allow motor to cool before storing in any enclosure.
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TOB-120,TOB-300
Owner’s Manual
Preparation for Operation
WARNING: Failure to follow all instructions could result in personal injury and/or damage to unit. Remove
wire from spark plug before attempting any adjustment or assembly procedures.
Instructions contained in this manual apply to several models. Use the instructions that apply to your unit.
Fuel Mixture
IMPORTANT: 2-cycle engines require that oil be mixed with fuel. Refer to Fuel in Operation section of this
manual for recommended mixture.
Handle Assembly
Model 120
Place handle (throttle lever up) into position on joint pipe holder with
notch on end of handle against handle stopper. Secure to joint pipe
holder with wing head bolt, lock washer, two plain washers, and Hair
Pin. Attach throttle cable to carburetor bracket.
Model 300
Place handle (throttle cable down) into position on clutch case. Be sure
flat of handle is set in notch of handle stopper. Secure to clutch case
with 8 x 30 bolt, lock washer, and two plain washers. Attach throttle
cable to carburetor.
Gear Housing
Check gear housing for proper level of grease prior to operation. See Lubrication and Maintenance section for
proper procedures.
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TOB-120,TOB-300
Owner’s Manual
6
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TOB-120,TOB-300
Owner’s Manual
Operation
PRE-STARTING
IMPORTANT: 2-cycle engines require that oil be mixed with gasoline (refer to Fuel section below for proper
mixture).
CAUTION:
Make sure all hardware is tight, all safety devices are in place and operating, all adjustments are
made correctly, that Stop Switch on models equipped with them, stops motor and that Throttle
Lever moves freely.
Fuel
IMPORTANT: Failure to mix oil with gasoline will result in seizure and severe damage to motor. DO NOT use
gasohol or gasoline containing alcohol because alcohol will attack and cause internal parts to deteriorate. Use
unleaded gasoline for best performance.
NOTE: To prevent foreign particles from entering tank while filling: wipe dust, dirt and debris from around cap
before removing it.
WARNING:
Gasoline is highly flammable and must be handled with care. Allow motor to cool several
minutes before removing fuel tank cap. Never fill tank when motor is running or hot from
operation. Do not allow open flame, matches, or smoking in area. DO NOT overfill. Wipe up any
spills and allow vapors to dissipate. Use approved (Red) gasoline container.
Tanaka 2-cycle oil has been formulated to insure maximum motor performance and increased motor life.
Premix Tanaka oil per instructions on container. If Tanaka oil is not available, select a quality 2-cycle approved
oil and use unleaded gasoline.
If oil manufacturer does not recommend a specific mixing ratio, mix at a 1 to 50 ratio (2.6 ounces oil per
gallon of unleaded gasoline). Always use branded 89 octane unleaded gasoline.
NOTE: After fuel mixture has been left standing for a prolonged
period of time it will begin to separate, therefore thoroughly shake
mixture before using.
Mounting To Boat
Motor must be mounted in center of boat transom. Recommended
transom height is 20". Clamp to transom with clamp stud handles
turned hand tight. Secure unit to transom using a safety
chain (not supplied).
During operation, occasionally check clamps for tightness. Loose
clamps may result in damage to motor or boat.
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TOB-120,TOB-300
Owner’s Manual
Tilt Adjustment
Motor tilt must be adjusted to propel boat through the
water with an even keel. If the motor is tilted too far
outward, bow of the boat would ride too high in the water
obscuring the operator's view and be susceptible to
sudden movement by high winds and waves. If the motor
is tilted too far inward, the bow may dig into high waves
or wakes.
A 12 to 15 degree tilt is recommended. This angle may
need to be adjusted according to the weight of boat and
passengers.
Improper transom height or tilt angle may result in boat
"porpoising" or motor cavitation.
Boat porpoising is a condition where the bow of the boat
raises and falls rapidly and continuously.
Motor cavitation is a condition where turbulent air passes by the propeller resulting in an increase in motor
speed coupled with a rapid drop in boat speed. These conditions can also be caused by fast turns, rough
water, wrong or obstructed propeller, or poor boat design.
To adjust, stop motor and allow propeller to come to a full stop. Tilt motor all the way up to the storage
position, then remove Tilt Lock Bracket Pin. Re-position lock pin in one of five angle adjustment holes in clamp
bracket. Secure Tilt Lock Pin with Hair Pin.
To determine the best motor tilt angle, start with the Tilt Lock Adjustment Pin in the center set of holes. In
calm water, operate boat at full throttle with a normal load. Adjust tilt angle as necessary to establish a near
even keel.
Steering Adjustment
The amount of resistance to movement of the steering
handle is adjustable. Loosen or tighten the steering
tension bolt using an open end spanner wrench
(supplied).
IMPORTANT: The tension bolt may fall out if loosened
too
much.
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TOB-120,TOB-300
Owner’s Manual
STARTING
CAUTION: DO NOT attempt to start motor at this time. Familiarize yourself with controls to
see what they do, how they work and thoroughly read and understand entire Owner's manual
first.
WARNING: Insure all guards and safety devices are installed and working properly before
starting.
WARNING: Rotating propeller can cause serious Injury. Be sure propeller is clear of
swimmers, waders, or underwater objects because when Throttle is set at starting position
motor speed will be fast enough for clutch to engage and propeller to rotate.
Fuel
When starting motor, open Air Vent Screw on Fuel Filler Cap. Open Fuel Shut Off Valve.
Choke
If starting a cold motor, move Choke Lever to its START (ON) position.
After motor begins to fire, move choke lever to its RUN (OFF) position.
IMPORTANT: Continued over choking while engine is running may
cause spark plug to foul.
Flooding is a condition where motor will not start due to an
overabundance of fuel in crankcase. If flooding occurs, move choke
lever to RUN position, set throttle at half and pull rewind starter
handle until engine starts and continues to run.
Throttle Lever
Model 120
Move Throttle lever to a half open position.
Model 300
Move twist grip handle to half throttle position.
WARNING: Starting motor may Immediately engage propeller
clutch resulting In a sudden movement of the boat. Be sure all
passengers are seated before starting motor.
NOTE: Allow motor to warm up at idle speed for 2 to 3 minutes before
applying load.
WARNING: After motor Is started and Is Idling smoothly,
propeller must not rotate. A rotating propeller can cause severe
personal Injury.
See Adjustment Section for Carburetor Adjustment.
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TOB-120,TOB-300
Owner’s Manual
Rewind Starter
Grasp Rewind Starter handle and pull rope slowly until
you feel some resistance, then pull rope with a rapid
stroke and allow rope to rewind slowly. Repeat above
instructions until motor starts.
CAUTION: Never start motor at full throttle or
stand up while starting motor.
WARNING: When motor starts, propeller may start
to rotate at a high rate of speed. Reduce Throttle
speed Immediately. Failure to do so may result In
loss of control of the boat and may cause severe
personal Injury.
IMPORTANT: If motor does not stop immediately when
Stop Button is depressed, move Choke Lever to its OFF
(closed) position to stop motor. Have Stop Button
serviced before restarting unit.
IMPORTANT: Do not release starter rope and let it
snap back against housing.
STOPPING
IMPORTANT: If motor will not be used for long periods
of time, tilt motor up to storage position, or removed
from boat. The following procedures should be used to
prevent fuel spillage. 1) Close fuel shut off valve. 2)
Close air vent on fuel fill cap. 3) Allow motor to run until
it stops on its own.
For normal stopping, move Throttle Lever or twist grip
to IDLE position and allow motor to run at idle speed for
a few minutes so that motor parts can cool evenly. To
shut off, move Throttle Lever to full OFF position. For
model 300, depress Stop Button.
CAUTION: Remove wire from spark plug to prevent
accidental starting or unauthorized use of unit.
Salt Water Operation
Operation in salt water will result in accumulation of salt
or mineral deposits on exposed motor parts. To prevent
corrosion of motor, take the following steps.
Set unit upright to drain water. Remove spark plug and
pour 2 ounces of oil in plug hole. Install plug but not
plug wire. Set motor upright and pull recoil starter rope
rapidly 2 or 3 times to distribute oil over internal
surfaces. Have unit serviced as soon as possible
Always tilt motor out of the water when not in use.
Never leave lower unit in salt water overnight.
Rinse exterior of unit with fresh water and wipe dry.
Apply a thin coating of oil over unit.
Inspect unit daily and apply a light coating of grease
to components which show signs of corrosion.
Always tilt motor by lifting on rear of shroud. Do not
push down on handle.
Operation after Submersion
A motor which has been entirely submerged in water
must be completely disassembled and cleaned before
operation. Disassembly should be done by a certified
Tanaka technician. To avoid corrosion of internal parts,
this should be accomplished as soon after recovery as
possible. If certified Tanaka service is not immediately
available, proceed as follows.
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TOB-120,TOB-300
Owner’s Manual
Lubrication and Maintenance
Maintenance, replacement, or repair of the emission control devices and systems may be performed by any
non-road engine repair establishment or individual.
Your Tanaka Dealer will be happy to provide any service required to keep your Outboard Motor operating at
peak efficiency.
CAUTION: Stop motor, wait for moving parts to stop and disconnect spark plug wire before attempting any
lubrication or maintenance procedures.
CAUTION: DO NOT touch motor or drive parts which might be hot
from operation. Allow such parts to cool before servicing unit.
Shear Pin Replacement
Insure that motor has stopped, wire from spark plug is removed, and
unit has cooled down.
A shear pin through the propeller shaft is designed to prevent damage
to the drive train if the propeller strikes an underwater object. The
shear pin will not prevent damage to the propeller which may also
require replacement after striking an object.
When the pin is sheared, motor will continue to run but the boat will
stop movement. Shut off motor immediately to prevent damage to unit.
To replace shear pin, remove cotter pin which holds propeller against
shear pin. Remove propeller and inspect for damage. Replace if
necessary. Lubricate shaft with lithium grease. Shaft should be lubricated
every 30 to 60 days. Inspect gear case for damage and have serviced if
necessary. Replace broken shear pin and reassemble propeller and cotter
pin.
Fuel Filter
Model 120
Fuel filter is located just above fuel shut off valve knob. To remove
filter, turn valve OFF. Remove fuel inlet bolt just above knob. Rinse
inlet screen and bolt assembly in warm water with detergent. Rinse
thoroughly several times until all traces of detergent are eliminated.
Allow assembly to air dry before re-installing.
Model 300
Turn fuel shut off valve to OFF position. Unscrew sediment bowl, then
remove 0-ring and screen from valve and clean as described above for
model 120.
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TOB-120,TOB-300
Owner’s Manual
Motor Cooling
The motor is air cooled, and air must circulate freely around motor and over cooling fins on cylinder head to
prevent overheating.
Once a year or every one hundred (100) operating hours, more often if conditions require) clean fins and
external surfaces of motor of dust, dirt and oil deposits which can contribute to improper cooling.
IMPORTANT: DO NOT operate motor with motor shroud or muffler guard removed as this will cause
overheating and motor damage.
Spark Plug
Spark plug should be cleaned or replaced (if necessary) and gap reset to
.023" (.6 mm) every 100 hours of operation or yearly whichever comes
first.
To clean, remove any oil or dirt from area around spark plug base,
remove spark plug from motor. In a smooth running motor, plug will have
brown colored electrodes. Scrape and wash with a commercial solvent.
Allow to air dry. Do not sand blast clean.
NOTE: Arcing can occur if wire terminal does not fit firmly on spark plug.
Reform or replace terminal as needed.
Test for faulty ignition system by removing spark plug from engine.
Connect plug wire and hold plug electrode against bare metal part of
motor (away from spark plug hole). Pull recoil starter rope several times.
If spark jumps gap of electrode, ignition system is in good condition.
Muffler
Muffler and exhaust pipe direct noise and motor exhaust under water.
Periodically check muffler and pipe for proper operation and carbon
buildup. Disassemble and clean out carbon buildup if necessary. Replace if
damaged.
CAUTION: Worn out or corroded mufflers are dangerous. Continued
use could result In loss of hearing, fire or explosion.
Gear Housing
Check gear housing for proper level of grease after first 4 hours of operation
and every 50 hours thereafter. See Storage section for annual maintenance.
To check and fill unit with gear oil, pull motor out of the water and place in an
upright position. Remove spark plug wire. Remove housing drain plug and
washer. Insert nozzle of lubricant tube fully into hole and squeeze tube until
excess oil flows from around nozzle. Replace plug and washer. Tighten securely.
NOTE: Use 90 weight Hypoid Gear Oil.
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TOB-120,TOB-300
Owner’s Manual
Adjustments
Carburetor
IMPORTANT: To prevent damage to carburetor, have idle
adjustment performed by an trained professional. Tanaka
company recommends that you take your unit to your Tanaka
dealer when these adjustment are necessary.
Model 120
Carburetor has a fixed high speed jet screw which is preset at
factory and does not need adjustment.
Model 300
Carburetor is preset at the factory, however, due to weather
changes or after extended use it may require idle adjustment.
WARNING: Accurate carburetor adjustment must be made with
motor running. The propeller will spin during carburetor
adjustment. Stay clear of propeller at all times and observe all
safety instructions.
To adjust carburetor, start motor using proper starting procedures, and allow unit to run a few minutes to
reach operating temperature. Move Twist Throttle Grip handle all the way off, to idle position. Turn IDLE
adjustment screw clockwise to increase motor speed, counter-clockwise to decrease motor speed. When idle
speed is properly set, propeller should not rotate and motor will continue to run.
Model 300 incorporates an automatic duel clutch design which allows the propeller to rotate very slowly or
stop completely when motor is idling. A sub clutch engages at slow speeds and the main clutch engages at
approximately 6 MPH.
Model 120 utilized a direct drive system.
Storage
reinstall cover and refill with grease as described
under Lubrication and Maintenance.
Store unit in an upright position on a sturdy stand.
Your authorized Tanaka Dealer is trained and
equipped to service your unit. A periodic checkup
by your dealer will help reduce your maintenance
costs.
Pull recoil starter rope until a slight resistance is felt
then slowly release rope. At this point, the piston is
covering intake an exhaust ports of the chamber.
If Tanaka 2-cycle oil is not used, we recommend
stabilization of the fuel with an anti-oxident fuel
stabilizer, such as Sta-Bil", a product of Gold Eagle
Co. Follow directions on the product label.
Otherwise the fuel should be drained before
storage. Run motor out of fuel as described in
Operation Section.
Clean unit thoroughly. Touch up all areas to
prevent rust.
Inspect unit for visible signs of wear, breakage or
damage. Order any parts required and make
necessary repairs to avoid delays when beginning
use again.
Drain gear housing and refill with new lubricant to
remove moisture and prevent possible corrosion of
internal parts. To drain, remove propeller and shear
pin. Remove gear housing cover. Drain grease,
Cover unit and store it in a dry moisture free area.
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TOB-120,TOB-300
Owner’s Manual
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