Tohatsu tiller arm replacement: how to swap the handle and add a longer reach extension
A loose, sticky, or damaged tiller can ruin control and comfort. Here is what to check, how replacement normally works, and how a longer reach tiller extension can improve steering on small boats and inflatables.
On many smaller Tohatsu outboards, the tiller arm is your throttle, steering, and engine control point. If the handle feels loose, the throttle grip binds, or the kill switch and wiring are damaged, replacing the tiller arm assembly (or fitting a reach extension) can make the engine safer and far nicer to use.
When a tiller arm should be replaced:
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Excess play in the pivot, cracked plastic, or a bent arm after a knock.
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Throttle grip does not return smoothly, or the friction adjuster no longer works.
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Perished wiring to the stop switch, start button, or gear shift controls (model dependent).
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Poor ergonomics on a tender or small RIB where you are forced to sit too far forward.
Longer reach tiller extension (why it helps):
A tiller extension lets you sit in a better position for trim and balance, often improving comfort and sometimes planing behaviour on lightweight hulls. It is especially useful on inflatables and small open boats where the standard handle is too short.
Fitment tips for ordering the right part:
Confirm your Tohatsu model and horsepower, shaft length, and the engine serial number range. Tiller assemblies vary between generations and between portable and mid-range engines. If you are fitting an extension, make sure it clamps securely without stressing the throttle grip or twist mechanism, and check full lock steering left and right without the extension fouling anything.
After installation, test throttle movement, friction adjustment, and kill switch operation before launching.
