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TOHATSU M 2.5A2, Owner'S Manual

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TOHATSU M 2.5A2 Owner'S Manual Download Page 2

Copyright © 2011 Tohatsu Corporation. All rights reserved. No part of this manual may 
be reproduced or transmitted in any from or by any means without the express written 
permission of Tohatsu Corporation.

READ THIS MANUAL  BEFORE  USING THE OUTBOARD  MOTOR.  FAILURE TO  FOLLOW THE 
INSTRUCTIONS  AND  SAFETY  PRECAUTIONS  IN THIS  MANUAL  CAN  RESULT  IN  SERIOUS 
INJURY OR DEATH. KEEP THIS MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE.

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Summary of Contents for M 2.5A2

Page 1: ...MANUAL OWNER S OB No 003 11045 6 M 2 5A2 3 5A2 3 5B ...

Page 2: ...ed in any from or by any means without the express written permission of Tohatsu Corporation READ THIS MANUAL BEFORE USING THE OUTBOARD MOTOR FAILURE TO FOLLOW THE INSTRUCTIONS AND SAFETY PRECAUTIONS IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH KEEP THIS MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE ...

Page 3: ... registration TO THE EXTENT PERMITTED BY APPLICABLE LAW YOUR OUTBOARD MOTOR WILL NOT BE COVERED BY THE APPLICABLE LIMITED WARRANTY IF THIS PROCEDURE IS NOT FOLLOWED PRE DELIVERY CHECK Be sure that the product has been checked by an authorized TOHATSU dealer before you take delivery Limited Warranty Please refer to the TOHATSU outboard motor Limited warranty provided to you with this product the te...

Page 4: ...proud owner of an excellent outboard motor that will service you for many years to come This manual should be read in its entirety and the inspection and maintenance procedures described later in this manual should be followed carefully Should a problem arise with the outboard motor please follow the troubleshooting procedures listed at the end of this manual If the problem persists contact an aut...

Page 5: ...motor position in tilt up 29 8 Mooring the boat 29 6 REMOVING AND CARRYING THE OUTBOARD MOTOR 30 1 Removing the outboard motor 30 2 Carrying the outboard motor 30 3 Storing the outboard motor 31 7 TRAILERING 32 8 ADJUSTMENT 33 1 Steering friction 33 9 INSPECTION AND MAINTENANCE 34 1 Daily inspection 35 2 Periodic inspection 41 3 Off season storage 43 4 Pre season check 43 5 Motor submerged in wate...

Page 6: ......

Page 7: ...ERATING PREPARATIONS 5 ENGINE OPERATION 6 REMOVING AND CARRYING THE OUTBOARD MOTOR 7 TRAILERING 8 ADJUSTMENT 9 INSPECTION AND MAINTENANCE 10 TROUBLESHOOTING 11 TOOL KIT AND SPARE PARTS 12 OPTIONAL ACCESSORIES 13 PROPELLER TABLE 1 2 3 4 5 6 7 8 9 10 11 12 13 GENERAL SAFETY INFORMATION INDEX ...

Page 8: ...d use of the Emergency Stop Switch tether Failure to observe will result in severe personal injury or death and possibly property damage Note This instruction provides special information to facilitate the use or maintenance of the outboard motor or to clarify important points Failure to observe could result in personal injury or property damage Failure to observe could result in severe personal i...

Page 9: ...rm service or maintenance on this outboard motor Be sure to use genuine parts genuine lubricants or recommended lubricants MAINTENANCE As the owner of this outboard motor you should be acquainted with correct maintenance procedures It is the operator s responsibility to perform all safety checks and to ensure that all lubrication and maintenance instructions are complied with for safe operation Pl...

Page 10: ...r exhaust Lubrication Engine Fuel Mixture Fuel Mixing Ratio 50 1 Cooling System Forced water cooling Starting System Recoil starter pull rope Ignition System Flywheel Magneto C D Ign tion Spark Plug NGK BP6HS 10 BPR6HS 10 Trim Position 4 Engine Oil Genuine moror oil or recommended one TCW III Gear Oil Genuine Gear Oil or API GL5 SAE 80 to 90 approx 3 5B2 180mL 3 5A2 2 5A2 90mL Fuel Tank Capacity L...

Page 11: ...ket Drive Shaft Housing Propeller Water Inlet 3 5B2 only Starter Handle Shift Lever Handle Grip Carrying Handle r t y u i o p a s d f g h Clamp Screw Thrust Rod Oil Plug Upper Anti Ventilation Plate Water Inlet 3 5B2 only Gear Case Oil Plug Lower Throttle Lever Tilt Stopper Stop Switch Carburetor Cover Choke Lever Drive Shaft Housing Grommet 3 5B2 only 2 5A2 3 5A2 3 5B2 ...

Page 12: ...ransom matching 1 Be sure that the anti ventilation plate of the outboard motor is 30 50mm 1 2 2 in below the water surface If the above condition cannot be met due to the shape of the bottom of your boat please consult your authorized dealer Bottom of hull Anti Ventilation Plate 30 50 mm 1 2 2 in 2 To attach the outboard motor to the boat tighten the clamp screws by turning their handles Also ret...

Page 13: ...nting bolts can lead to the release or displacement of the outboard motor possibly resulting in lost of control and or serious personal injury Be sure that fasteners are tightened to the specified torque 30 Nm 3 0kgf 13ft lb Check the fasteners for tightness from time to time Be sure to use outboard mounting fasteners included in the outboard motor package or their equivalents in terms of size mat...

Page 14: ... When carrying a fuel tank containing gasoline Close the air vent screw of fuel tank cap or gasoline vapor will be emitted through the air vent screw creating a fire hazard Do not smoke When or before refueling Stop the engine and do not start the engine during refueling Do not smoke Be careful not to overfill fuel tank Wipe up any spilled gasoline immediately When or before cleaning the gasoline ta...

Page 15: ...eteriorate the properties of the lubricant If the use of gasoline containing alcohol is inevitable or presence of alcohol is suspected in the gasoline it is strongly recommended to add a filter that has water separating capability and check the fuel system for leaks and mechanical parts for corrosion and abnormal wear more frequently And in case any of such abnormality is found discontinue the use...

Page 16: ...unning is 1 25 Mixing Ratio Engine Oil Gasoline During break in 1 25 After break in 1 50 0 6L 0 012 0 6 0 024 0 6 0 024 1 2 0 048 1 2 0 1L 1 2L 1 5L 0 005L 0 0 010L 0 015L 0 020L 0 025L 0 030L 0 035L 0 040L 0 045L 0 050L 0 055L 0 060L Oil 1 25 1 50 Gasoline Fuel by Oil Mixing 1 25 1 50 Fuel drain plug of carburetor Notes Always use fresh gasoline Fuel kept in the fuel tank for a long period will p...

Page 17: ... cap on the container and close tightly 4 Shake the container to mix engine oil and gasoline well and even 5 Pour the mixture into fuel tank Do not use other than two stroke engine oil with specified grade or the engine may be damaged Do not use fuel prepared in other than specified mixing ratio Lack of engine oil can cause severe engine trouble such as piston seizure Excess of engine oil can shorte...

Page 18: ...e opon throttle After completing 5 hours of break in replace the gear oil with new oil Refer to Changing the gear oil in subsection 2 Periodic Inspection 18 4 3 Break in Note Proper break in allows outboard motor to deliver it full performance for longer service life Do not operate the outboard motor in closed area or area with no forced ventilation Exhaust gas emitted by this outboard motor conta...

Page 19: ...ture The tank has a capacity of approx 1 4 liters permitting the engine to be operated for 30 to 40 minutes Be careful not to spill any fuel on board If any fuel or gasoline is spilled wipe it up thoroughly for safety 2 Loosen the air vent screw on the tank cap 3 Make sure that the shift lever is in the NEUTRAL position 3 5B2 only Shift lever N F In case engine starts in gear do not start cruising...

Page 20: ...ngine just after the engine has stopped never set the choke lever to the CLOSE position If the choke lever is set to the CLOSE position excess fuel will be supplied to the carburetor leading to difficulty in starting the engine 6 Set the throttle lever to the START position START 7 Ease out the recoil starter grip slowly until you feel the ratchet engage then give it a sharp tug Note Return the rec...

Page 21: ... Remove the top cowl by releasing the screws and remove the recoil starter from the top of the fuel tank Wrap a rope around the starter pulley about 3 times then pull quickly to start Use a 10 mm socket wrench as a rope handle Be careful that your clothes or other items do not get caught in the rotating engine parts To prevent accident and injury do not re attach the recoil starter after the engin...

Page 22: ...e the engine starts running Never touch the spark plug or high tension cable when the engine is running since they are carrying high voltage electricity Avoid high speed running for safety A medium or low speed is recommended taking care not to splash water on the fuel tank or electrical parts Once the engine has been started never attach the engine cover etc to avoid danger If the recoil starter ...

Page 23: ...or reverse make sure that boat is properly moored and outboard motor can be steered fully to the right and left Make sure that no swimmer s is ahead or astern of the boat Attach other end of emergency stop switch tether to the operator s clothing or arm and keep it attached during cruising Do not attach the tether to a part of clothing that can be torn easily when pulled Arrange the tether so that...

Page 24: ...OW position and when the engine speed has reached the lowest rpm move the shift lever to the NEUTRAL N position Stand the steering handle upright and turn the motor 180 Move the shift lever to FORWARD F for reverse running 3 5B2 only needs to operate shift lever Before shifting FORWARD reduce the engine speed to the idling low speed 3 5B2 only It is dangerous to run at high speed while reversing B...

Page 25: ...trike outboard motor against sea bottom or propeller may be pushed out of water resulting in loss of control Do not tilt up or down outboard motor when swimmer s or passenger is near to prevent them from being caught between outboard motor body and clamp bracket in case the outboard motor body falls Do not tilt up outboard motor while engine operates or no cooling water may be fed leading to engin...

Page 26: ...ch the engine will stop The engine will not start if the lock is in released condition The emergency stop line should be connected to the driver s wrist so that the engine will shut down if the emergency stop line is disconnected from the switch in the event of an accident such as the driver being thrown overboard or the boat capsizing Be careful not to entangle the emergency stop line when operat...

Page 27: ...roper trim angle Set the thrust rod higher if the bow of the boat is below horizontal 5 27 Do not put hand or finger in between outboard motor body and clamp bracket when adjusting trim angle to prevent injury in case the outboard motor body falls Unsuitable trim position can cause loss of control of boat When testing a trim position run boat slow initially to see if it can be controlled safely Ex...

Page 28: ... cooling water 6 Tilt up and tilt down 28 5 When tilting up or down be careful not to place your hand between the swivel bracket and the clamp bracket Be sure to tilt the outboard motor down slowly Note Stop the engine before tilt up or tilt down operation Tilt down Pull the outboard motor fully toward you and release the tilt stopper knob from the tilt up position Do not tilt up or down outboard ...

Page 29: ...rect position 7 Outboard motor position in tilt up When tilting up or down be careful not to place your hand between the swivel bracket and the clamp bracket Be sure to tilt the outboard motor down slowly If the engine will not be operated for a period of time or the boat is moored in shallow water tilt up the motor to prevent damage to the propeller gear case etc due to hitting rocks in the water...

Page 30: ...G THE OUTBOARD MOTOR Close air vent screw of fuel tank and fuel cock before carrying or storing outboard motor and fuel tank or fuel may leak potentially catching fire Engine may be hot immediately after operating and could cause burns if touched Allow Engine to cool down before attempting to carry the outboard 2 Carrying the outboard motor Keep the outboard motor in a vertical position when carry...

Page 31: ...If the outboard motor must be laid down be sure the tiller handle faces down as shown in the drawing below Elevate power unit 2 inches to 4 inches if traveling to avoid oil spillage Do not carry or store outboard motor in any of positions described below Otherwise engine damage or property damage could result from leaking oil ...

Page 32: ...supported by support bar or accidental fall of outboard motor could lead to severe personal injury Close air vent screw of fuel tank and fuel cock before carrying or storing outboard motor and fuel tank or fuel may leak potentially catching fire When taking outboad motor from package or removing outboad motor from the boat never release the lock lever If the lock lever is released it will very eas...

Page 33: ... or remote control tensioner or it could result in difficulty of movement resulting in the loss of control causing an accident and could lead to severe injury Note The steering adjust screw is used to adjust the friction load of the steering but not to fix the steering Excess tightening of the adjustment screw may cause damage to the swivel bracket Light Heavy Heavier Lighter ...

Page 34: ...ribed in this section The maintenance intervals shown in the checklist apply to an outboard motor in normal use If you use your outboard motor under severe conditions such as frequent full throttle operation frequent operation in brackish water or for commercial use maintenance should be performed at shorter intervals If in doubt consult your dealer for advice We strongly recommend that you use on...

Page 35: ...p Remedy or replace Correct or replace Clean or replace Recoil Starter Check the rope for wear and chafing Check the ratchet engagement Replace Correct or replace Clutch and Propeller System Visually Check propeller for bent or damaged blades Check the propeller nut is tightened and the spl t pin is present Replace Installation of Motor Check all the bolts attaching the motor to the boat Check the ...

Page 36: ...nd odorless gas which can be fatal if inhaled for any length of time Do not start engine without removing propeller or accidentally turning propeller could cause personal injury Keep cooling water passage free of clogs or lack of cooling water flow could lead to engine overheating potentially resulting in engine trouble Note It is recommended to check chemical properties of water on which your out...

Page 37: ... inlet located in the gear case with tape 3 Insert a hose connected to a water tap into the flushing plug and let the water running 4 Put the shift lever in the neutral position and start the engine 5 Make sure of cooling water flowing out of water pump indicator hole and continue engine running for 3 to 5 minutes 6 Stop the engine and water supply Remove the flushing plug and tape and then reinsta...

Page 38: ...shaft 2 Remove the shear pin from the shaft 3 Install a new shear pin Notes When removing the plug cap cover take care not to drop it into the water In order to protect propeller and gears from damage shear pin is designed so as to be broken when propeller gets strong impact or when the shear pin is used for a longer period of time Always carry a spare split pin and shear pin When the spare has be...

Page 39: ...sket surface and use a new gasket Wipe off any dirt from the threads and screw in the spark plug to the correct torque 1 Stop the engine 2 Remove the top cowl 3 Remove the spark plug caps 4 Remove the spark plugs by turning it counter clockwise using a 21 mm 13 16 in socket wrench and handle Socket wrench Never remove the plug cap cover when the engine is running It is dangerous to touch the high ...

Page 40: ...ghten the anode attaching bolt As it is likely to be subjected to electrolytic corrosion Anode Be sure that outboard motor is secured to transom or service stand or accidental drop or fall of outboard motor could lead to severe personal injury Be sure to lock outboard motor if it is tilted up or accidental fall of outboard motor could lead to severe personal injury Do not go under outboard motor t...

Page 41: ... Remarks 10 hours or 1 month 50 hours or 3 months Every 100 hours or 6 months Fuel system Carburetor Clean and adjust Fuel filter Check and clean or Replace Piping Check and Replace Fuel tank Clean Ignition Spark plugs Check gaps Remove carbon depos ts or Replace Starting system Starter rope Check for wear or chafting Lower unit Propeller Check for bent blades damage wear Shear pin Split pin Check ...

Page 42: ...to a pan 2 Insert the oil tube nozzle into the lower oil plug hole and fill with gear oil by squeezing the oil tube until oil flows out of the upper plug hole 3 Install the upper oil plug and then remove oil tube nozzle and install the lower oil plug Upper oil plug Lower oil plug Do not reuse oil plug gasket Always use new gasket and tighten oil plug properly to prevent entry of water into lower uni...

Page 43: ... hole Pull the recoil starter handle a few times to circulate the oil to the internal parts 5 Apply grease to the propeller shaft 6 Change the gear oil in the gear case 7 Apply grease to all sliding parts bolts and nuts 8 Wipe off any water and salt on the electrical components using a dry cloth 9 Stand the outboard vertically in a dry and ventilated place Be sure to use cloth to remove fuel remai...

Page 44: ...at in cold weather at temperatures below 0 C 32 F there is the danger of water freezing in the cooling water pump which may damage the pump impeller etc To avoid this problem submerge the lower half of the outboard motor into the water or tilt the motor up above water level and pull the recoil starter several times to drain the water completely 6 Cold weather precautions Striking the sea bottom or...

Page 45: ...idling Engine speed abnormally high Engine speed abnormally low High engine speeds not possible Overheating of engine Possible cause FUEL SYSTEMS Empty fuel tank Incorrect connection of fuel sysytem Air entering fuel line Deformed or damaged fuel pipe Closed air vent on fuel tank Clogged fuel filter fuel pump or carburetor Use of improper engine oil Use of improper gasoline Excessive oil in mixture...

Page 46: ...RIC SYSTEMS Spark plugs other than specified Dirt soot etc on spark plugs No spark or weak spark Short circuit of engine stop switch Lock plate not fitted to stop switch OTHERS Sheared shearpin Insufficient cooling water flow clogged or defective pump Cavitation or ventilation Incorrect propeller selecition Damaged and bent propeller Improper thrust rod position Unbalanced load on boat Transom too hig...

Page 47: ...r Items Quantity Remark Service Tools Tool Bag Pliers Socket Wrench Socket Wrench Handle Phillips Screwdriver 1 1 1 1 1 21mm No 2 Spare Parts Spark Plug Shear pin Spl t Pin Rope 1 1 1 1 NGK BPR6HS 10 Not provided w th the motor in some markets 11 47 TOOL KIT AND SPARE PARTS ...

Page 48: ...Flushing plug 48 12 OPTIONAL ACCESSORIES Genuine gear oil 500mL Propeller Touch up Paint Genuine Engine Oil 0 4L 1L 4L 20L ...

Page 49: ...sured at wide open throttle while cruising is within the recommended range Model 2 5A2 3 5A2 3 5B2 Propeller 4 5 Plastic OP Propeller 6 Plastic STD STD OP Propeller 6 Aluminum OP OP OP Propeller 7 Plastic OP STD O Option STD Standard A stainless steel shear pin must be used 13 49 PROPELLER TABLE ...

Page 50: ...M E M O ...

Page 51: ......

Page 52: ...ddress 5 4 3 chome Azusawa Itabashi ku TOKYO 174 0051 JAPAN Phone TOKYO 03 3966 3117 FAX TOKYO 03 3966 2951 Website www tohatsu co jp 003 11045 6 1101NB Printed in Japan OWNER S OB No 003 11045 6 M 2 5A2 3 5A2 3 5B M2 5 3 5_E_cover_110111 indd 1 11 1 17 6 43 37 PM ...

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