TOHATSU M 40 Page 87 Owner'S Manual Download

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Summary of Contents for M 40

Page 2: ...Copyright 2007 Tohatsu Corporation All rights reserved No part of this manual may be reproduced or transmitted in any form or by any means without the express written permission of Tohatsu Corporation...

Page 3: ......

Page 4: ...ccessories Please read this manual carefully and use the product in accordance with the instructions set forth herein Serial Number Please record the serial number of the engine indicated on the lower...

Page 5: ...vey sears strong currents or high winds Loss of control while mooring is another potential hazard To prevent such hazardous situation the line is curled and will extend to a full I 300mm WARNING As th...

Page 6: ...n authorized TOHATSU service shop perform servicing or main tenance on this product Be sure to use original Tohatsu parts and Tohatsu lubricants only MAINTENANCE As the owner of this outboard engine y...

Page 7: ...21 4 Connecting Cords and Cables 25 S Installing the Meters 25 6 Installing the Drag Link Assembly 28 IBattely 2 9 3 Fuel Oil and Engine Oil 3i 1Non Auto mixing model M40D M40DEF 32 M50DEF 2 Auto mixi...

Page 8: ...Adjustment 68 10 Inspection and Maintenance 69 I Daily Inspection 69 2 Periodic Inspection 73 3ChangingGearOil 7 5 4Cleaning the Filters 76 5 Checking and Refilling Oil in the Power Trim Tilt Unit 77...

Page 9: ...Max output KW PS Full Throttle Speed Range 4OPS 4 500 5 500 0 0 1 V...

Page 10: ...recoil hand starter and electric starter starter electric starter break pointless CD Ignition Spark plugs M40D NGK B7H S 10 or Champion L 82 1 O mm gap M50D NGK BBHS IO or Champion L 78 1 O mm gap I I...

Page 11: ...per Lever 6 Water Plug 7 Anti Cavilation Plate 8 Trim Tab 9 Propeller 10 Oil Plug lower 11 Water Strainer 12 Oil Plug upper 13 Stern Bracket 14 Thrust Rod 15 Clamp screw 18 Thronle Grip 17 Shift Lever...

Page 12: ...M4oDEF MSODEF 17 Shift Lever IS Starter Handle 19 sdety Switch 20 Choke knob 21 Reverse locking Lever 22 Main Switch 23 Battery Cords 24 Anode...

Page 13: ...r Check Porl 5 ill Slopper Lever 8 Waler Plug 7 Anti Cavilalion Plale 8 Trim Tab 9 Propeller 10 Oil Plug lower 11 Water Slrainer 12 Oil Plug upper 13 stern Bracke 14 Thrus Rod 15 Clamp Screw IS Thmnle...

Page 14: ...r Plug 7 rut Cawtatla Plate 8 Trim Tab 9 Propeller 10 Oil Plug lower 11 Water Strainer 12 011 Plug upper 13 Stern Bracket 14 Thrust Rod 15 Clamp Screw 16 Thronle Grip 17 Shin Lever 18 Starter Handle 1...

Page 15: ...rt 5 Tilt Stopper Lever 6 water Plug 7 Anti Cavitation Plate 8 Trim Tab 9 Propeller 10 Oil Plug lower 11 Water Strainer 12 Oil Plug upper 13 Stern Bracket 14 Thrust Rod 15 Clamp screw 15 Choke Knob 17...

Page 16: ...M4ODEPTO MSODEPTO...

Page 17: ...e I AA WARNING I Do not operate the engine until it has been securely mounted on the boat in accordance with the instruction below 1 Installation 0 Sigle engine Installation n Position the outboard en...

Page 18: ...rence exceeds 0 30mm 0 I 18 in engine power perfromance is likely to be reduced as a result of mcreased water resistance to the gear case assembly Attaching the Stem Bracket After positioning the Stem...

Page 19: ...rring to the dtmentional drawing 2 Stern Bracket Dimentional Drawing manual tilting model M40D M40DEF M40DEFO M40DEPO M50DEF M50DEFO M50DEPO 12mm x lenglh 93mm with the Power Trim and Tilt model M40DE...

Page 20: ...ard while the nut5 are kept on the outside of the boat to prevent mjury to thepnsxngers NOTES 1 Apply sealing agent such 01 silicon sealer behveen the bolts and the transom board holes when tightening...

Page 21: ...Remote Control cable length Use distances A and B as depicted in the illustrations as guide lines for the Remote Control cable length and add an additional 300mm one foot cable length A B 300mm one fo...

Page 22: ...at least llmm 0 43 in of the Remote Control cables through the terminal eyes A Securely lock the terminal eyes with lock nuts B Engage the outer groove of the shift cable on the Remote Control side w...

Page 23: ...e shift arm pin into the terminal eye and lock it with the E ring E ring Shift arm pin Connect the throttle cable to the throttle arm in the same way cable was connected Reinstall the back plate as th...

Page 24: ...0 Install the Remote Control Box using the three screws spacers washers and nuts Washer I Nut 3 Connecting the Remote Control Cable to the engine Detach the upper engine cover by turning the lever 21...

Page 25: ...es Having fixed the Remote Control Cables to the bracket tie them to the lower engine cover Bracket I screw hrottle Cable Shift Cable Datach thethrottle and shift cable joints by removing the R shaped...

Page 26: ...and then set the lever to Neutral I Double check that the Remote Control Cables the throttle cable and shift cable have been connected correctly Move the Remote Control Lever Forward until the first e...

Page 27: ...act with the stopper of the carburetor throttle valve to enable it to be fully closed 0 Adjust cable joint until the hole meets with the Advancer Arm pin After adjustment lock a cable joint with a nut...

Page 28: ...as this will damage the C D unit and could result in a serious electric I 5 Installing the meters Install the meterz securely in the dashboard where they can be easily read and are not exposed to wate...

Page 29: ...All models of the M40D and MSOD series have six electric poles Set the tachometer selector knob to 6P Cut holes with 85mm 3 346 in diameter for the tachometer and 52 5mm 2 067 in for the trim meter 26...

Page 30: ...on of leads Tachometer EPO EPTO Trim meter EPTO Trim sender EPTO Color Code B black L blue Lg light green 0 orange P pmlc R red Sb sky blue W while Y yellow The parts of mark is to be wired when a Met...

Page 31: ...the steering cable manufacturer spacers optional may by I required Connect the Drag Link Rod to the tip of the steering cable Tighten the rod using self locking nut making sure the rod can swing free...

Page 32: ...necting the battery always disconnect the negative cable first Required battery rating 12V 70AH I2V IOOAH NOTES 1 Bnftery cables should be of sufficient lenght to allowfree movement of the engine 2 Ke...

Page 33: ...e smoking and other sources of fire must be avoided in the charging area to prevent explosion of the battery 0 The battery fluid electrolyte contains sulfuric acid If electrolyte is spilled on the ski...

Page 34: ...oil sold at gas stands since the octane rating and oil grade are unknown Fueltank capacity 22 7 litters 6 U S gal Engineoil Use genuineTOHATSU Outboard Engine Oil If this oil is not available useanoth...

Page 35: ...40DEPTO M50DEFO M50DEFTO MSODEPO MSODEPTO The required amount of engine oil is automatically supplied from the oil tank through the oil pump according to the engine running conditions Gasoline is fed...

Page 36: ...lamp on the front portion of the lower engine cover lights if the engine oil level falls bellow 0 4 liters 0 I05 U S gal When the buzzer mounted on engine starts to sound MSODEFO M50DEFTO Pilot lamp o...

Page 37: ...any spilled oil afterward with a rag TOHATSU Engine Oil SU Oil tank cap A CAUTION 1 In the unlikely event that gasoline by mistake is filled into the oil tank drain the oil tank completely and consul...

Page 38: ...the oil pump If present purge the air as follows W Loosen the air vent screw on the oil pump to purge the air and tighten it when all air as seen through the vinyl pipe on the oil pump side has been p...

Page 39: ...Maxspeed 4Soo rpm must not cruising at 2 500 rpm 3 000 rpm Apply full minimum to to exceed speed thronle W M50D 5 700 3 000 rpm 4 000 rpm for one minute in M40D 5 500 every 30 rpm minutes 0 Fuel mixin...

Page 40: ...ine only after the first 10 hours of break in have passed and the tank is completely emptied 2 Starting board to avoid fire or explosion 1 rlON I resulting from spilled gasoline If gasoline is ever sp...

Page 41: ...down if the stop line switch is disconnected This is a safety measure designed to protect the driver from propeller injury if he is thrown overboard The engine will not start unless this switch has be...

Page 42: ...oling water If the cooling water supply is insufficient cylinder wall scratch and damaae of water zurnD imDeller are likelv o 1 Startmg M40D A Set the shift lever to Neutral NOTE I B Turn the throttle...

Page 43: ...e engineis warm I D Pull the starter rope slowly until resistance is met Give it a sharp tug to start the engine E Turn the handle grip to its original position gradually once the engine has started F...

Page 44: ...EFTO MSODEF M50DEFO M50DEFTO A Set the shift lever to Neutral Engine will only stari whenlheshift lever is sefto Neutral position I B Turn the throttle grip so that the indicator line meet the START m...

Page 45: ...e ignition key to ON and further clockwise turning makes the electric starter working ON E Release the ignition key as soon as the engine star The key will return to the ON position automatically F Pu...

Page 46: ...gain 2 NEVER operate the starter motor once the engine has started 3 If the starter maor won t turn over check that the battery terminal connectioru are tight and the battery is fur y charged 0 3 Star...

Page 47: ...not be pushed if the engine is warm NOTE Thefree acceleratorlever is inoperative unlesstheRemoteControl lever is setto Neutral 4 While keeping the key pressed turn it to START 1NOTE 1 If the engine is...

Page 48: ...es not start waitfor IO seconds before operating the starter motor again 2 NEVER operate the starter motor once the engine has started 3 If the stoi ter motor won t turn over check that the battery te...

Page 49: ...e Recoil Starter Assembly M40D 40DEF M40DEFO M40DEFTO M50DEF take off the Flywheel Cova M40DEPO M40DEPTO M50DEPO M50DEPTO M50DEFO M50DEFTO 3 Pull the choke knob 4 l Turn the throttle grip so that the...

Page 50: ...Lift up the free accelerator lever to z of its stroke M40DEPO M40DEPTO M50DEPO MSODEPTO 5 Turn the ignition key to ON M40DEPO M40DEPTO M40DEF M40DEFO M40DEFfO M50DEPO MSODEPTO M50DEF M50DEFO M50DEFTO...

Page 51: ...r nor the Upper Engine Cover after the engine is started with the stalter rope In this case be sure nobody sits in the vicinity of the engine and run carefully Immediately contact an authorized TOHATS...

Page 52: ...40DEF M40DEFO M40DEFTO M40DEPO M40DEPTO Standard equipment MSODEF MSODEFO M50DEFTO M50DEPO M50DEPTO The overheat buzzer will sound if the engine tempenture exceeds the preset level The engine speed wi...

Page 53: ...gine must be at idling speed when the shift Lever is moved from Forward to Reverse or vice versa 2 Before moving the Shift Lever to Reverse make sure the Reverse Lock and the Tilt Stopper are engaged...

Page 54: ...e lever IS moved further forward or backward the throttle will open A CAUTION 1 The engine must be at idling speed when the Shift Lever is moved from Forward to Reverse or vice versa 2 Before movimg t...

Page 55: ...hallow water 2 Pay attention that the cooling water inlet port on the gear case assembly is always below water level when running using the shallow water setting I M40D M40DEF M40DEFO M40DEPO M50DEF D...

Page 56: ...ghtly and then let it go down The shallow water setting is then released c The engine is released from shallow water setting and be locked at normal running position 2 M40DEFTO M40DEPTO MSODEFTO M50DE...

Page 57: ...pull out the lock plate The engine will then stop 2 M40DEF M40DEFO M40DEFTO MSODEF MSODEFO MSODEFTO Reduce the engine speed to idling r p m Turn the Main Switch to OFF keep pressing on the Safety Swit...

Page 58: ...tion key counter clockwise or pull out the safety switch The engine stops The engine can also be stopped by pressing on the safety switch i 4 NOTES I Whenthe enginestopped closetheair vent screwonthef...

Page 59: ...OD ramnect the fuel connector from the engine Close the air vent screw on the fuel tank cap 56...

Page 60: ...t thrust rod hole n Proper Trim Angle The trim angle is optimum when the boat is parallel to the water surface while running n Improper Trim Angle bow rises too high If the trim angle is excessive the...

Page 61: ...adjusted to set the desired trim angle of the engine in relation to the transom shape planning speeds and load It is imperative that the trim angle is adjusted conectly Incorrect adjustment will cause...

Page 62: ...reference n Improper Trim Angle bow rises too high If the trim angle is excessive the bow will rise out of the water and the speed will decrease Furthermore the bow may sway or the bottom may slam the...

Page 63: ...dip into the water the speed will decrease and water may enter the boat In this case the trim angle should be increased by flicking the switch on the Remote Control Lever to UP W Proper Trim Angle Th...

Page 64: ...r a long time or when mooring in shallow water tilt the engine up to prevent damage on the propeller and gear Casey 1 M40D M40DEF M40DEFO M40DEPO MSODEF MSODEFO M50DEPO Disconnect the fuel connector f...

Page 65: ...y turning it downwards Tilt the engine up entirely The tilt will lock in the raised position To tilt the engine down Turn the Tilt Stopper Lever upward toward LOCK Tilt the engine up slightly and then...

Page 66: ...from the engine Operate the Power Trim Tilt switch on the Remote Control Lever and tilt the engme up The Main Switch must be ON The engine can also be tilted up using the switch provided under the Lo...

Page 67: ...the battery is dead and the Power Trim Tilt Switch thus inoperative turn the manual valve a few turns in the Manual directions This will allow manual tilting of the engine A CAUTION Screw the manual v...

Page 68: ...fire and explode Be sure to fully discharge gasoline from the carburetors when transporting the engine Wipe off spilled gasoline with a rao Disconnect the Steering Cable the Remote Control Cables the...

Page 69: ...n carrying or putting the engine up for storage make sure the side with the electric pump of the Power Trim and Tilt down otherwise air will enter the pump system for the Power Trim and Tilt operation...

Page 70: ...g can not be achieved adjust the trim tab located under the anti cavitation plate W If the boat veers toward the right direct the trim tab towards A q If the boat veers toward the left direct the trim...

Page 71: ...clockwise to increase the load Turn counter clockwise to decrease the load M40D M40DEF M40DEFO M40DEPO M50DEF M50DEFO M50DEPO M40DEFTO M40DEPTO M50DEFTO M50DEPTO 4 Throttle Grip Turning Load Adjustmen...

Page 72: ...place 0 Check if Ihe battery electrolyte level and specific Replenish gravity are normal or recharge 0 Check for loose connections on battery terminal Retighten Check if the safety switch functions no...

Page 73: ...hose to the flushing plug and flush out with water Be sure to securethe water strainer and sub water strainer on the gearcasebeforehand Flushmg plug Scaling tape I AA WARNING I I To prevent rotation o...

Page 74: ...t and washer 2 Remove the propeller by pulling toward you 3 Apply genuine TOHATSU grease to the propeller shaft before mounting the new propeller 4 Fit the washer securely tighten the nut and insert t...

Page 75: ...re hard to turn Spark plug 0 s 1 Omm A CAUTION Do not touch the high tension cords running from the ignition coil to the spark plugs while the engine is running or it is turned by the electric starter...

Page 76: ...ry Every Every 30 50 100 tours hours hours J E or 1 or 3 or 6 nonth months month5 I I 0 0 0 0 0 0 0 3 0 0 OI I0 II 0 0 0 i I What to do Remarks Check and clean Remove carbon Adjust the timing Check fo...

Page 77: ...2 Grease Nipples Power Trim 0 0 splace 0 0 0 0 0 0 0 0 0 0 CC 0 0 0 0 0 0 0 Replenish or hange if required Check for water entry 3HATSI 5 x oil IOCC Tighten properly 0 Apply and pump in grease 0 0 0 C...

Page 78: ...e gear oil completely Insert the oil tube nozzle into the lower oil plug hole and squeeze the tube until the oil flows out of the upper plug hole Install the upper oil plug Then remove the oil tube no...

Page 79: ...r SAE 8OW Reauired volume CZDD OX 5OOcc 16 89 U S fluid 02 4 Cleaning the Filters Fuel filters are provided inside the fuel tank and on the engine 1 Remove the fuel tank housing by loosening the four...

Page 80: ...ank as shown on the right while the tank is kept in a vertical position Tilt the engine up to check the oil level in the tank Remove the oil plug by turning counter clockwise then check if the oil lev...

Page 81: ...r Tilt Tilt unit will cause poor tilting movement With the engine mounted on the boat set the manual release valve to the Manual side and tilt the engine manually up down 5 6 times while checking the...

Page 82: ...ke sure it is evenly distributed Drain all oil from the engine oil tank and the engine oil filter cup Clean the filer element with kerosene or a special cleaning liquid before storage Othenvise the oi...

Page 83: ...the battery Specific Gravity st 20 Terminal Voltage V Charge Condition 1 120 10 5 Fully discharged 1 160 11 1 114 charged 1 210 11 7 l 2 charged 1 250 12 0 34 charged 1 280 13 2 Full charged Check th...

Page 84: ...r Oil from another manufacturer 2 Warm up the engine for 3 minutes while keeping the Remote Control lever at Neutral 3 Run the engine for 5 minutes at slow speed 4 Run the engine for 10 minutes at hal...

Page 85: ...start the engine However the electrical components and carburetors will soon deteriorate and become inopemtive Therefore be sure to have the engine overhauled by a TOHATSU service shop as soon as poss...

Page 86: ...starts canrd Over Power to s an but Poor running normally normally obtain beating Trim speed idling or high low hlgh engine slops engine engine engine 0 Tilt inopera 500 engine speed speed speeds eng...

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Page 88: ...r rope 1 BOOrnrn Spark Plug Slit Pin Bracket Fixing Bolts Srackeet Fixing Nub Washers A B Fuel Tank with primer bulb Flushing Plug Remo e Conwol BOX Drag Link Tachometer Trim meter Lead Wire for Meter...

Page 89: ...the propeller should much the boat type and its load lark Standard propeller on the model 7 8 5 9 10 11 12 M40D Lc and UC transom C 12 5 M40D s and L transom M50D LL and UC transom 13 C 13 5 M50D s an...

Page 90: ...18 OPTIONAL ACCESSORIES 1 Speedometer 2 Speedometer SOMPH p5MPH 6 Hour Meter engine operation hour counter 8 Tachometer 87...

Page 91: ...13 Propeller 14 TOHATSU Engine Oil SUPER GOLD brand 5 lilers 1 3 U S gallons 15 TOHATSU Grease sag 2509 16 TOHATSU Gear Oil 26Oc z 500 17 Touch up Spray 88...

Page 92: ...11 Power trim tilt solenoid switch B 12 Trim sender 13 Fuse 14 Choke solenoid 15 Oil level sensor 16 Over heat sensor 17 Water temperature sensor 18 Battery cord 19 Cord assembly 20 Cord assembly B 2...

Page 93: ...41 Volt meter 42 Water temperature meter 43 Fuel meter 44 Fuel gauge sensor unit 45 Fuel meter cord 46 Water temperature lead 47 Meter lamp switch 48 Assist cord black 49 Assist cord red 50 Assist cor...

Page 94: ...i 22 UP ON...

Page 95: ...MODEL EPO EPTO 91...

Page 96: ...CM4001 18 I UP ON I 7 18 96...

Page 97: ...MODEL F EF EFO EFTO...

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Page 99: ...arTOHATSU CORPORATION Address 4 8 3 chome Azusavia Itabashihu TOKYO 174 Japan Cable 70HAT W TOKYO Telex 272 2051 THT J Pacslmlle TOKYO 03 X9 7885 GII GIII Phone TOKYO 03 956 3111...

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TOHATSU M 40, Owner'S Manual

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