Re: tohatsu 3.5 won't run without choking
You did not adequately clean the carb. Carb spray itself it not aggressive enough to dissolve the organic varnishing in the low-speed passages. You must completely disassemble it (including jets, emulsion tube nozzle, and of course the needle and float). Then submerge in real carb dip for 4 hours at room temperature. THEN blow it out with generic carb spray, and reassemble, paying close attention to the float height.
You did not need to adjust the pilot mixture screw. But, since you did... It should not bottom out the spring; it should Gently seat in a delicate brass jet in the carb. The correct initial setting is about 1-3/4 turn out, and once the motor is running OK and fully warmed, you would then adjust it as on any other carb on any other motor. If you are not familiar with that procedure, or don't have a very good ear and a razor-accurate shop tach, get assistance from someone who does. Yes, you must pull the fuel tank bolts to make that adjustment... But since you are "never" supposed to change it, that's not a big deal.
There is in fact an inline filter screen between the fuel **** and the tank, which should be inspected.
Paul Van Voorhees
Certified Tohatsu TLDI Technician
Mgr, Obersheimer Sails
Buffalo, NY USA