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TOHATSU M 40D2, Owner'S Manual

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TOHATSU M 40D2 Owner'S Manual Download Page 2

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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.

Copyright © 20

1  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.

Summary of Contents for M 40D2

Page 1: ...O W N E R S M A N U A L M 50D2 Original instructions M 40D2 OB No 003 11038 JBA1...

Page 2: ...ONS IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH KEEP THIS MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE Copyright 20 1 Tohatsu Corporation All rights reserved No part of this manual may be r...

Page 3: ...uthorized TOHATSU service shop or dealer All information in this manual is based on the latest product information available at the time of approval for printing Tohatsu Corporation reserves the right...

Page 4: ...he responsible person Name Title Date and place of issue ENON00937 0 Note For CE marked model The Outboard engine is intended to install on non recreational craft within the European Union because it...

Page 5: ...ion to such information to ensure safe operation of the outboard motor at all times ENOW00001 0 Failure to observe will result in severe personal injury or death and possibly property damage ENOW00002...

Page 6: ......

Page 7: ...rse and acceleration 48 6 Stopping the engine 50 7 Steering 52 8 Trim angle 53 9 Tilt up and down 55 10 Shallow water operation 57 8 REMOVING AND CARRYING THE OUTBOARD MOTOR 59 1 Removing the outboard...

Page 8: ...11 TROUBLESHOOTING 83 12 TOOL KIT AND SPARE PARTS 85 13 PROPELLER TABLE 86...

Page 9: ...L LOCATIONS 5 INSTALLATION 6 PRE OPERATING PREPARATIONS 7 ENGINE OPERATION 8 REMOVING AND CARRYING THE OUTBOARD MOTOR 9 ADJUSTMENT 10 INSPECTION AND MAINTENANCE 11 TROUBLESHOOTING 12 TOOL KIT AND SPAR...

Page 10: ...stop switch The stop switch lanyard is the coiled red cord with the stop switch lock on one end and a metal clip on the other end With attaching the stop switch lanyard to the operator s body part or...

Page 11: ...e operation Please comply with all instructions concerning lubrication and maintenance You should take the engine to an authorized dealer or service shop for periodic inspection at the prescribed inte...

Page 12: ...ual tilt z z z z M 50 D 2 E P T O L Model descrip tion Horse powe r Product genera tion Minor change Starter system Steering system Tilt system Lubrication system Shaft length M X Two stroke A and up...

Page 13: ...4 2 68 x 2 52 Piston Displacement cm3 Cu in 697 42 53 Exhaust System Through hub exhaust Cooling System Forced water cooling Lubrication System Engine oil mixed gasoline Starting System Manual Ignitio...

Page 14: ...ations subject to change without notice Tohatsu outboard is power rated in accordance with ISO8665 propeller shaft output Operator Sound Pressure ICOMIA 39 94 dB A 91 2 Hand Vibration Level ICOMIA 38...

Page 15: ...50 Engine Type 2 Stroke Number of Cylinder 3 Bore x Stroke mm in 68 x 64 2 68 x 2 52 Piston Displacement cm3 Cu in 697 42 53 Exhaust System Through hub exhaust Cooling System Forced water cooling Lubr...

Page 16: ...Tab 9 Propeller 10 Oil Plug lower 11 Water Strainer 12 Oil Plug upper 13 Clamp Bracket 14 Thrust Rod 15 Clamp Screw 16 Throttle Grip 17 Throttle Friction Screw 18 Shift Lever 19 Starter Handle 20 Sto...

Page 17: ...3 Oil Plug upper 14 Clamp Bracket 15 Thrust Rod 16 Clamp Screw 17 Throttle Grip 18 Throttle Friction Screw 19 Shift Lever 20 Starter Handle 21 Stop Switch 22 Choke Knob 23 Pilot Lamp 24 Main Switch 25...

Page 18: ...e 8 Trim Tab 9 Propeller 10 Oil Plug lower 11 Water Strainer 12 Oil Plug upper 13 Clamp Bracket 14 Thrust Rod 15 Clamp Screw 16 Choke Knob 17 Filler Lid 18 Fuel Connector 19 Battery Cords 20 Anode 21...

Page 19: ...9 Trim Tab 10 Propeller 11 Oil Plug lower 12 Water Strainer 13 Oil Plug upper 14 Clamp Bracket 15 Thrust Rod 16 Choke Knob 17 Filler Lid 18 Fuel Connector 19 Battery Cords 20 Power Trim Tilt 21 Anode...

Page 20: ...trol box Fuel tank 1 Control Lever 2 Neutral Lock Arm 3 PTT Switch 4 Free Throttle Lever 5 Main Switch 6 Stop Switch 7 Stop Switch Lock 8 Stop Switch Lanyard 9 Fuel Gauge 10 Air Vent Screw 11 Fuel Tan...

Page 21: ...21 4 LABEL LOCATIONS ENOM01659 0 Warning label locations 8 9 7 6 5 1 2 3 4 ENOF01955 5...

Page 22: ...such as ignition coil or spark plug cord when starting or operating the engine HAZARD CAUSED BY ROTATING PARTS Rotating parts can cause severe injury Keep hands feet hair and clothing away from all mo...

Page 23: ...LABEL LOCATIONS 23 4 8 Warning regarding gasoline See page 30 9 Warning regarding gasoline See page 30 ENOF00005 M ENOF00005 F...

Page 24: ...CE marked model The Outboard engine is intended to install on non recreational craft within the European Union because it has not been confirmed compliance with requirement of Directive 2013 53 EU Se...

Page 25: ...o unsafe conditions such as poor maneuverability lack of control or fire z Loose clamp screws and or mounting bolts can lead to the release or displace ment of the outboard motor possibly resulting in...

Page 26: ...board motor mounting height or existence of underwater object s such as hull bottom design bottom surface conditions or underwater accessories can cause water spray possi bly reaching the engine throu...

Page 27: ...Washer large diameter 3 Washer small diameter 4 Nylon locking nut ENOW00008 B z Upper mounting bolts should be installed with the bolt head at inside surface of the transom Mounting bolts installed wi...

Page 28: ...he battery away from any source of fire sparks and open flames such as burners or welding equipment z Do not smoke near the battery when the battery is charging z Do not charge the battery when the el...

Page 29: ...curely fasten both the box and the battery so they do not shake loose 2 Connect the positive lead to the positive terminal of the battery and then connect the negative lead When disconnecting the batt...

Page 30: ...in the gaso line can absorb moisture from the air resulting in a separation of the water ethanol from the gasoline in the fuel tank These may cause increased z Corrosion of metal parts z Deterioration...

Page 31: ...ore refueling z Be sure to remove the static electricity charged in your body before refueling z The sparks due to static electricity may cause explosion of flammable gasoline z Stop the engine and do...

Page 32: ...NOW0002A A Use of engine oils that do not meet these requirements will result in reduced engine life and other engine problems ENOW00603 0 Do not mix different brands of oil Mixing dif ferent brands o...

Page 33: ...increase of noxious exhaust For quantities of engine oil and gasoline to be pre mixed refer to table in previ ous page When portable fuel tank is used for operation of outboard motor s 1 Pour engine o...

Page 34: ...n autho rized service shop for advice z Check the amount of oil in the oil tank visually before starting the engine Run ning out of oil at sea is a cause for poten tial disaster The required amount of...

Page 35: ...h the vinyl pipe connecting the oil tank with the oil pump If present Purge the air as follows Loosen the air vent screw on the oil pump to purge the air and tighten it when all air as seen through th...

Page 36: ...oduct If any abnormality is experienced during the break in z Discontinue the operation immediately z Have the dealer check the product and take proper action s if necessary ENOM01004 A Fuel mixing ra...

Page 37: ...gine will not be stopped See next page for conditions which will lead to an abnormal condition or fault ENOM00040 B Location of warning buzzer and lamp Warning buzzer RC model Located inside the remot...

Page 38: ...ite the spark plug therefore the engine speed varies and be controlled under 6300 min 1 rpm Low speed ESG Low speed ESG is a device to prevent the engine from getting damage If the engine has problems...

Page 39: ...ly and set the Remote Control Lever to Neutral buzzer will stop And then stop the engine Check the engine oil level and add engine oil if necessary Start the engine and move the Remote Control Lever F...

Page 40: ...is new or have been left without operation for a long time or just after the engine is overhauled be sure to execute the following operation for forcedly feeding the engine oil to the oil line before...

Page 41: ...es such as sun light 1 Full open the air vent screw on the fuel tank cap 1 Air vent screw 2 Fuel tank cap 2 Open the fuel tank cap slowly and release internal pressure completely After that close the...

Page 42: ...0 cm 4 in ENOW00036 0 Be sure to stop engine immediately if cooling water check port is not discharging water and check if cooling water intake is blocked Operating engine could lead to overheating po...

Page 43: ...ever in the Neutral position 1 Shift lever 2 Neutral 3 Set the throttle grip to START posi tion 1 Throttle grip 2 START position 3 Full closed 4 Full opened 4 Pull the choke knob fully 1 Choke knob EN...

Page 44: ...tarted The key returns to the original position automatically 1 ON 2 START 3 OFF 6 Return the choke knob fully after engine has started 7 Check the cooling water from cooling water check port 1 Coolin...

Page 45: ...r check port ENON00035 A Note The free throttle lever can not be raised when the control lever shift is in Forward or Reverse 1 Cooling water check port 2 Idle port ENOM00042 A Emergency starting ENOW...

Page 46: ...veral turns clockwise 5 Tie a loop in the another end of the emergency starter rope and attach socket wrench that is included in the tool kit ENOW00860 0 Be sure to keep the harness away from the rota...

Page 47: ...e s life 1 Cooling water check port 2 Idle port ENOM00044 A Engine speeds Idling speed after warming up ENOM00972 0 Free throttle lever Side mount RC type ENOW00956 0 z Keep the free throttle lever fu...

Page 48: ...amaged z Do not shift into Reverse during cruising or control may be lost falling down or causing passenger s to be thrown over board Leading to serious personal injury and steering system and or shif...

Page 49: ...ft lever to the Forward position Reverse 1 Turn the throttle grip to reduce engine speed 2 When the engine reaches trolling or idling speed quickly pull the shift lever to the Reverse position Acceler...

Page 50: ...lly 1 Control lever 2 Mine switch key ENOM00049 A ENOW00868 0 Be careful not to remove engine stop switch lanyard from engine accidentally while boat is running Sudden stop of engine can cause loss of...

Page 51: ...o the OFF position or push the stop switch Do not forget to turn the key off 1 ON 2 START 3 OFF ENOW00869 0 After stopping the engine z Close the air vent screw on the fuel tank cap z Disconnect the f...

Page 52: ...falls into water be sure to use emergency stop switch lock of the spare Be sure to confirm the spare stop switch lock is in the tool bag before begin to operate ENOM00920 0 ENOW00870 0 Sudden steering...

Page 53: ...gle before continuing cruise z For outboard motor model with PTT switch on the bottom cowl do not oper ate the switch during cruising or control of boat may be lost The trim angle of the outboard moto...

Page 54: ...show pic ture 1 Push in 2 Rise the stopper 3 Pull out 5 Reinstall the thrust rod in the desired position securely 6 Gentry tilt down the outboard motor Trim angle adjustment Power Trim Tilt type The t...

Page 55: ...nutes be sure to dis connect fuel hose or fuel may leak poten tially catching fire ENOW00057 0 Do not tilt up outboard motor while engine operates or no cooling water may be fed leading to engine seiz...

Page 56: ...opper after the outboard motor has been tilted up Tilt down 1 Release the tilt stopper from the set up position while slightly tilting up outboard motor 2 Operate the Power Trim Tilt switch and tilt t...

Page 57: ...elief valve is loosened in the Manual direction 1 POWER 2 MANUAL Manual relief valve specified tightening torque 1 8 N m 1 4 ft lb 0 18 kgf m ENOM00068 A ENOW00051 0 During shallow water operation be...

Page 58: ...down position 3 Tilt up position 2 Return to normal running position Put the reverse lock lever in the tilt down position slightly lift up the out board motor and then put it down 1 Reverse lock lever...

Page 59: ...st hooks to the engine hanger 5 Remove the outboard motor from boat and completely drain the water from the gear case ENOM00071 A ENOW00933 0 Be sure to disconnect fuel connector except when operating...

Page 60: ...ches if traveling to avoid oil spillage ENOM00072 C ENOW00072 0 Trailering in the tilted position may cause damage to the outboard motor boat etc ENOW00073 A Be sure to disconnect fuel connector excep...

Page 61: ...normal running position or on a transom saver bar Tiller handle type To prevent the outboard motor from moving when it is attached on a boat during transport on a trailer properly tighten the steering...

Page 62: ...turning the steering friction adjustment bolt 1 Steering friction adjustment bolt 2 Lighter 3 Heavier ENOM00074 A ENOW00074 B Do not overtighten the throttle adjustment screw or it could result in dif...

Page 63: ...lead to severe personal injury z Do not go under outboard motor tilted up and locked or accidental fall of outboard motor could lead to severe personal injury ENOW00075 0 Inappropriate adjustment of...

Page 64: ...and mainte nance procedures described in this sec tion z The maintenance intervals shown in the checklist apply to an outboard motor in normal use If you use your outboard motor under severe conditio...

Page 65: ...emedy or replace 1 Replenish or recharge Retighten Remedy or replace 1 Correct or replace 1 Throttle System Check if the choke solenoid and valve for the carburetor works normally Check if the carbure...

Page 66: ...er limit it can leak potentially leading to engine damage If the oil level is low or at lowest mark add recommended oil to the oil tank 1 Open the filler lid from the top cowl 2 Open the oil tank cap...

Page 67: ...tboard motor 2 Remove the water plug from the gear case and screw in the flushing attachment 3 Attach the flushing attachment and connect a water hose Turn on the water and adjust the flow Be sure to...

Page 68: ...y cable from the battery negative ter minal Failure to do so may cause a short circuit ENOW00924 0 Never use a fuse with a rating that exceeds the specified rating as this could cause seri ous damage...

Page 69: ...0 9 1 0 mm 0 035 0 039 in Ignition timing 1 z z Adjust timing Starting System Starter motor 1 z Check for salt deposits and battery cable condition Battery z z z Installation fluid quantity gravity St...

Page 70: ...cordance with local fire prevention and environ ment protection regulations z Install fuel filter with all related parts in place or fuel leak could occur leading to catching fire or explosion z Check...

Page 71: ...and or accidental drop or fall of outboard motor could lead to severe personal injury z Be sure to lock outboard motor if it is tilted up or accidental fall of outboard motor could lead to severe pers...

Page 72: ...ew gasket and tighten oil plug properly to pre vent entry of water into lower unit ENOW00928 0 Wipe off gear oil well immediately if spilled and dispose of it in accordance with local fire prevention...

Page 73: ...t holder 4 Apply water proof grease to the pro peller shaft before installing a new propeller 5 Install the thrust holder propeller stopper washer and propeller nut onto the shaft 1 Propeller 2 Thrust...

Page 74: ...or if the insulators are cracked or chipped 6 Measure the spark plug electrode gap with a wire type feeler gauge The gap should be 0 9 1 0 mm 0 035 0 039 inches If the gap is different replace the spa...

Page 75: ...lytic corrosion Anode is located on the gear case cylinder etc When the anode is eroded more than 1 3 of original size replace it ENON00029 0 Notes z Never grease or paint the anode z At each inspecti...

Page 76: ...vertical posi tion 1 Tilt the outboard motor up and lock the tilt with the tilt stopper 2 Remove the oil cap by turning counter clockwise then check if the oil level reaches the bottom line of the pl...

Page 77: ...INSPECTION AND MAINTENANCE 77 10 ENOM00960 0 Grease point Apply water proof grease to the parts shown below ENOF01928 0...

Page 78: ...oling water system thoroughly with fresh water Drain the water completely Wipe off any surface water with an oily rag 2 Remove the fuel hose from the out board motor 3 Drain all fuel from the fuel hos...

Page 79: ...commercially available first fill the fuel tank with fresh oil and fuel If the fuel tank is only partially filled air in the tank can cause the fuel to deteriorate during storage 1 Before adding fuel...

Page 80: ...ew 5 Tilt up the outboard motor until fuel flows out of the drain tube 6 Leave the outboard motor in this position until all fuel has been drained 7 When thoroughly drained retighten the drain screw s...

Page 81: ...ge inside the engine will be circulated out to assure optimum performance ENOM00105 D ENOW00098 0 Do not attempt to start submerged outboard motor immediately after it is recovered or engine could be...

Page 82: ...ine immediately 2 Check the control system gear case boat transom etc 3 Return to the nearest harbor slowly and carefully 4 Consult a dealer check the outboard motor before operation again ENOM00121 0...

Page 83: ...engine speed Abnor mally low engine speeds Cannot obtain high engine speeds Over heatingof engine z z z Empty fuel tank z z z z z z z Incorrect connection of fuel system z z z z z z z Air enters fuel...

Page 84: ...Transom too high z z z Transom too low z z z z z z Incorrect adjustment of throttle link z z z z z z Incorrect adjustment of ignition timing z Insufficient battery capacity loose terminals corrosion z...

Page 85: ...e Spare Parts Emergency starter rope 1 600mm Spare stop switch lock Spark Plug Split Pin 1 1 1 1 1 NGK BR7HS 10 40D2 NGK BR8HS 10 50D2 Diameter x Length 3 x 25mm Parts Packaged with Engine Mounting ha...

Page 86: ...rpm measured at wide open throttle while cruising is within the recommended range 40D2 50D2 5000 to 5800 min 1 rpm 40 50 Mark Propeller Size Diameter Pitch Inch mm Heavier Load Lighter Load 7 11 4 x...

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Page 89: ...O W N E R S M A N U A L 5 4 Azusawa 3 Chome Itabashi Ku Tokyo 174 0051 Japan Tel 81 3 3966 3117 Fax 81 3 3966 0090 www tohatsu com M 40D2 M 50D2...

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