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Tohatsu 40 issue

noelg11892noelg11892 Posts: 331 Deckhand
edited December 2021 in Boating #1
Ive had a 40 tohatsu for 2 years got it brand new. Ran a ton during covid 3-4 times a week. its happened 3 times now where after running for a while ill try to throttle back, it will either get stuck and won't go click into neutral, or it'll slide in with no tactile click into neutral. When it does go into neutral it'll high rpm to 2k about and come back down slowly its tough when docking and not something I want continuously happening but it runs fine other than that.  First time when I got the boat took it to the mechanic told me it was timing and its as fixed ran Fine for a while, then it happened again took it back they told me it was water in the gas got it back drained tank, ran fine (only ever use ethanol free, as well as kept under a roof not sure how water would get in as well as changing fuel water separator very regularly probably more than most), happened again recently after running perfect for 6 months, took it to a different mechanic and they kept it for 3 weeks worked their butts off on it, adjusted intake valves as well as changing IAC valve. They water tested it and say it was working great and I get it and it does the same thing. 

Any ideas, I'm very frustrated with this I just want it to work. its to the point that when it finally gets fixed I'm getting rid of the boat for something else. Ive read could be thermastat thinking the motors running hot so its idling high to cool off, Ive heard it could be Throttle positioning sensor being bad, and my thought was possibly the throttle control at the helm because I had to change the steering cables recently and thought possibly throttle cable could be bad as well. 

Its under warranty but I didn't really wanna lose it for another 3 weeks in the middle of duck season if its something I can possibly change myself. 

Edit: forgot to add the most recent mechanic didn’t find any sign of water


  • chaser48chaser48 Posts: 346 Deckhand
    Bite the bullet and turn for warranty repair
  • chaser48chaser48 Posts: 346 Deckhand
    turn in for warranty repair
  • noelg11892noelg11892 Posts: 331 Deckhand
    Already called em. No other choice
  • lemaymiamilemaymiami Posts: 4,911 Captain
    Something to remember about water in fuel... Your best defense is to always top off that tank before you put it away - any open space in your fuel tank can allow moist warm air to condense inside your tank - then drip down into your fuel where it will stay forever until it builds up enough to cause trouble... In addition... most simply don't use their skiffs enough and fuel that sits starts breaking down chemically within 30 days (and it gets worse the longer that old fuel sits..). That's where a bit of fuel conditioner might save you some heartache - ask your dealer's tech what he (or she) recommends... 
    Any troubles with clearing a gear and moving to neutral are purely mechanical (the same goes for your throttle sticking and not responding to a reduced throttle setting..). That's something that a skilled tech should sort out without much trouble -if they actually address the issue...   That sort of stuff is not something I'd ever expect to be considered a warranty issue on a two year old motor... 

    Good luck and post up how it goes.  Actually finding someone competent to work on your motor would be my biggest concern since there aren't that many Tohatsu dealers around (compared to the big three...).
    Tight Lines
    Bob LeMay
    (954) 435-5666
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