TOHATSU MFS 25d Owner'S Manual Download Page 1

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O W N E R’ S
M A N U A L

AAAA

MFS 30D

OB No.003-11172-0BB1

MFS 25D

Summary of Contents for MFS 25d

Page 1: ...O W N E R S M A N U A L AAAA MFS 30D OB No 003 11172 0BB1 MFS 25D ...

Page 2: ...hts 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 This product can expose you to chemicals including gasoline or LPG exhaust emissions which are known to the State of California to cause cancer and carbon monoxide which is known to the State of California to cause birth defects or other rep...

Page 3: ...e labels applied to your outboard motor You should keep this owner s manual where accessible while operating your out board motor If the outboard motor is resold make sure the manual is passed on to the next owner In case you encounter any problems please contact an authorized TOHATSU service shop or dealer for assistance Tohatsu Corporation reserves the right to change modify add or remove a part...

Page 4: ...er is identification of outboard motor and is located on the outboard motor as shown in the figures below The serial number is required for warranty registration filing a warranty claim as well as making technical inquiries and may be required for other occasions Therefore please write down the serial number and date of purchase in the space below Serial Number Serial Number Date of purchase ENOF0...

Page 5: ...tion 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 0 Failure to observe could result in severe personal injury or death or property damage ENOW00003 0 Failure to observe could result in personal injury or property damage ENON00001 0 Note This instru...

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Page 7: ...rward reverse and acceleration 48 5 Stopping the engine 50 6 Steering 53 7 Trim angle 53 8 Tilt up and tilt down 55 9 Shallow water operation 58 8 REMOVING AND CARRYING THE OUTBOARD MOTOR 60 1 Removing the outboard motor 60 2 Carrying the outboard motor 60 3 Trailering 61 9 ADJUSTMENT 63 1 Steering friction 63 2 Throttle grip friction 63 3 Remote control lever friction 63 4 Trim tab adjustment 64 ...

Page 8: ...8 Operation with multiple outboard motors 90 11 TROUBLESHOOTING 91 12 TOOL KIT AND SPARE PARTS 94 13 PROPELLER TABLE 95 14 EMISSION CONTROL SYSTEM INFORMATION 96 ...

Page 9: ...ALLATION 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 SPARE PARTS 13 PROPELLER TABLE 14 EMISSION CONTROL SYSTEM INFORMATION INDEX 2 3 4 5 6 7 8 9 10 11 12 13 14 1 ...

Page 10: ...ngine can be stopped by pulling out the stop switch lock from the 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 operator s personal flotation device PFD the engine will stop when the stop switch lanyard is being stretched and pulled out the lock ...

Page 11: ...of this manual See page 66 It is the operator s responsibility to perform all safety inspections proper lubrication and to follow all maintenance instructions for safe operation You should take the engine to an authorized dealer or service shop for periodic inspection at the prescribed intervals Correct periodic maintenance and proper care of outboard motor will reduce the chance of problems limit...

Page 12: ...om heights S z z z z z z L z z z z z z Basic Tiller Handle z z z z z z Multi function tiller handle z z Remote Control z z Power Tilt z z Gas assisted tilt Manual tilt z z z z F 30 D E T L Model description Horse power Product gen eration Starter system Tilt system Shaft length F Four stroke A and up E Electrical start M Manual start T Power tilt G Gas assist Blank Manual tilt S Short 15 in L Long...

Page 13: ...62 5 138 69 5 153 Engine Type 4 stroke Number of Cylinder 3 Piston Displacement cm3 cu in 500 30 50 Bore x Stroke mm in 61 x 57 2 40 x 2 25 Max Output kW PS 18 4 25 22 1 30 Max Operating Range min 1 rpm 25D 5000 6000 30D 5500 6500 Idle Speed min 1 rpm 850 Exhaust System Through hub exhaust Lubrication System Wet sump Cooling System Water cooling Starting System Electric and Recoil Ignition System ...

Page 14: ...AE 80 90 mL US Imp oz 460 15 6 16 2 PTT Fluid ATF Automatic Transmission Fluid Dexron III Battery minimum requirements 64Ah 5HR 70Ah 20HR 512CCA Spark Plug NGK DCPR6E equivalent Spark Plug Gap mm in 0 8 0 9 0 031 0 035 Intake Valve Clearance mm in 0 10 0 15 0 004 0 006 Exhaust Valve Clearance mm in 0 20 0 24 0 008 0 0095 Engine Oil Drain Bolt 24N m 17 ft lb 2 4 kgf m Engine Oil Filter 18N m 13 ft ...

Page 15: ...L kg lb 71 5 157 67 5 149 Engine Type 4 stroke Number of Cylinder 3 Piston Displacement cm3 cu in 500 30 50 Bore x Stroke mm in 61 x 57 2 40 x 2 25 Max Output kW PS 18 4 25 22 1 30 Max Operating Range min 1 rpm 25D 5000 6000 30D 5500 6500 Idle Speed min 1 rpm 850 Exhaust System Through hub exhaust Lubrication System Wet sump Cooling System Water cooling Starting System Electric and Recoil Ignition...

Page 16: ...PI GL 5 SAE 80 90 mL US Imp oz 460 15 6 16 2 PTT Fluid ATF Automatic Transmission Fluid Dexron III Battery minimum requirements 64Ah 5HR 70Ah 20HR 512CCA Spark Plug NGK DCPR6E equivalent Spark Plug Gap mm in 0 8 0 9 0 031 0 035 Intake Valve Clearance mm in 0 10 0 15 0 004 0 006 Exhaust Valve Clearance mm in 0 20 0 24 0 008 0 0095 Engine Oil Drain Bolt 24N m 17 ft lb 2 4 kgf m Engine Oil Filter 18N...

Page 17: ... ventilation Plate 7 Trim Tab 8 Sub water Inlet 9 Propeller 10 Oil Plug Lower 11 Cooling Water Inlet 12 Oil Plug Upper 13 Splash Plate 14 Anode 15 Clamp Bracket 16 Clamp Screw 17 Basic Tiller Handle 18 Throttle Grip 19 Shift Lever 20 Recoil Starter Handle 21 Oil Filter 22 Fuel Filter 23 Spark Plug 24 Oil Filler Cap 25 Flushing Connector Cap 26 Warning Lamp 27 Stop Switch 28 Stop Switch Lanyard 29 ...

Page 18: ...rim Tab 8 Sub water Inlet 9 Propeller 10 Oil Plug Lower 11 Cooling Water Inlet 12 Oil Plug Upper 13 Splash Plate 14 Anode 15 Clamp Bracket 16 Clamp Screw 17 Stop Switch 18 PT Switch 1 19 Start Switch 20 Shift Lever 21 Throttle Grip 22 Recoil Starter Handle 23 Oil Filter 24 Fuel Filter 25 Spark Plug 26 Oil Filler Cap 27 Flushing Connector Cap 28 Warning Lamp 29 Basic Tiller handle 30 Stop Switch La...

Page 19: ... Trim Tab 9 Sub water Inlet 10 Propeller 11 Oil Plug Lower 12 Cooling Water Inlet 13 Oil Plug Upper 14 Splash Plate 15 Anode 16 Clamp Bracket 17 Stop Switch 18 PT Switch 19 Main Switch 20 Shift Lever 21 Throttle Grip 22 Recoil Starter Handle 23 Oil Filter 24 Fuel Filter 25 Spark Plug 26 Oil Filler Cap 27 Flushing Connector Cap 28 Warning Lamp 29 Multi function Tiller handle 1 30 Stop Switch Lanyar...

Page 20: ...Remote control box Fuel tank 1 Control Lever 2 Neutral lock arm 3 PT 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 Tank Cap 12 Tab Lock 13 Primer Bulb 14 Fuel Connector Fuel tank side ...

Page 21: ...21 4 LABEL LOCATIONS ENOM00019 A Warning label locations 1 2 8 14 15 11 13 9 5 3 4 12 10 6 7 7 ENOF02506 A ...

Page 22: ...p See page 35 5 Engine stop switch See page 41 50 and 52 6 When laying down the out board motor be sure this decal is facing up For multi function tiller handle model 7 Stop switch See page 42 and page 52 For RC model 8 Engine stop switch warning 9 Warning regarding gasoline 3WL 72180 0 3 2 1 4 3NV 72181 1 3UR 72187 1 ENOF00130 0 ENOF00131 B 3H6 67572 1 3GF 72200 1 ENOF00008 1 ENOF00005 E ...

Page 23: ...arning regarding gasoline See page 30 13 Warning regarding fuel tank cap See page 31 14 Warning tag regarding combination of fuel tank and primer bulb ass y See page 38 15 Warning tag regarding instructions of the fuel tank cap See page 38 ENOF00005 L ENOF00005 M ENOF00005 F ENOF00012 0 ENOF00005 T ENOF00011 0 ...

Page 24: ... the control of air pollution from new out board engines This certification is con tingent on certain adjustments being set to factory standards For this reason the factory procedure for servicing the prod uct must be strictly followed and wher ever practicable returned to the original intent of the design Maintenance replacement or repair of the emission control devices and sys tems may be perfor...

Page 25: ...tor without following this manual can lead to unsafe conditions such as poor maneuverability lack of control or fire z Loose clamp screws and or mounting hardware can lead to the release or dis placement of the outboard motor possi bly resulting in loss of control and or serious personal injury Be sure that fas teners are tightened to the specified torque Check the fasteners for tightness before o...

Page 26: ...is mounted incorrectly water may intrude the engine from openings of the bottom cowl while cruising Exposing the engine to such con dition may result in severe damage to the engine ENOM00832 A Mounting the outboard motor Manual tilt type 1 Set the outboard motor to appropri ate position 2 Tighten the clamp screws by turning their handles 3 Secure the clamp brackets to the transom board using bolts...

Page 27: ...2 105 2 Washer small diameter 3 Nylon locking nut 4 Washer large diameter ENOW00008 2 z Install upper mounting bolts from the boat side Exposing threaded side of bolts on the boat side can casue personal injury z Tighten the bolts securely otherwise the outboard motor could fall down ENON00948 0 Note z Apply sealing agent such as silicone sealant between the bolts and the transom board holes befor...

Page 28: ... is charging z Do not charge the battery when the elec trolyte level is low Otherwise the bat tery will be damaged and may cause malfunction ENOW00014 0 z Make sure that the battery leads do not get stuck between the outboard motor and boat when turning etc z The starter motor may fail to operate if the leads are incorrectly connected z Be sure to correctly connect the and leads If not the chargin...

Page 29: ...remove the negative lead first After connecting the positive terminal securely place a cap on it to prevent short circuits 1 Battery cord red 2 Battery cord black ENOM00971 0 TOCS Tohatsu Onboard Communication System interface coupler can provide information regarding engine speed fuel consumption and various malfunction via an optional interface cable Contact authorized Tohatsu dealer for more de...

Page 30: ...eparation of the water ethanol from the gasoline in the fuel tank Use of gasoline containing ethanol may accelerate z Corrosion of metal parts z Deterioration of rubber or plastic parts z Fuel permeation through rubber fuel lines z Starting and operating difficulties If the use of gasoline containing ethanol cannot be avoided or presence of etha nol is suspected in the gasoline it is rec ommended ...

Page 31: ... remove the static electricity charged in your body before refueling z The static electricity may ignite the gaso line vapor during refueling z Stop the engine and do not start the engine during refueling z Do not smoke z Be careful not to overfill fuel tank Wipe up any spilled gasoline immediately When or before cleaning the gasoline tank z Dismount fuel tank from the boat z Place the fuel tank a...

Page 32: ...imit marks of dip stick drain oil to level lower than upper limit z Be sure that outboard motor is upright when checking or changing oil z Stop the engine immediately if low oil pressure warning lamp or oil leak is found or engine could be severely damaged Consult your dealer z Wipe off engine oil well immediately if spilled and dispose of it in accordance with local fire prevention and environ me...

Page 33: ...or SL Engine oil viscosity must be selected from the following chart according to the average temperatures in your area ENOW0002A A Use of engine oils that do not meet these requirements will result in reduced engine life and other engine problems 1 2 3 ENOF02510 0 2 1 ENOF02511 0 Engine oil volume with out oil filter replacement Approximately 1500 mL 1 6 1 3 US Imp qt CAUTION 10W 40 10W 30 C F 40...

Page 34: ...d side of emis sion ENOW00023 1 Operating the outboard motor without break in can shorten life 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 ENON00008 2 Note z During Break in run the outboard motor at varied RPM less than specified engine speed Not following the proce dure may...

Page 35: ...tion or fault ENOM00040 A Location of warning buzzer and lamp Warning buzzer RC model Located inside the remote control Multi Function tiller handle model Located in the tiller handle Tiller handle model Located in the engine cover Warning lamp LED RC model Located in the tachometer bottom cowl Multi Function tiller handle Tiller han dle models Located on the bottom cowl ENON00009 A Note Warning l...

Page 36: ...s activated not to ignite the spark plug Therefore the engine speed varies and is controlled following specified engine speed MFS 30D 6700 min 1 rpm MFS 25D 6200 min 1 rpm Low speed ESG Low speed ESG is a device to prevent the engine from getting damage If the engine has problems regarding cooling water oil pressure and sensors the low speed ESG is activated not to ignite the spark plug and disabl...

Page 37: ... dealer if the engine oil level is too low or too high 3 Move to safe place quickly and check if cooling water is discharged from the water check port at idle speed and stop the engine Remove any foreign matter on the gear case and propeller if necessary Consult an authorized dealer if no discharge of cooling water 4 Consult an authorized dealer ENOW00985 0 z Low speed ESG ON Engine speed will be ...

Page 38: ...low the procedure described below Fuel could blast out if the fuel tank cap is opened by using another procedure when internal pressure of fuel tank is raised by heat from sources such as sun light ENOW00030 B When using EPA approval fuel tank only use a primer bulb hose assembly that has a Fuel Demand Valve FDV installed in the fuel hose or a sealing mechanism in the fuel connector as shown below...

Page 39: ...1 Fully 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 fuel tank cap Connector type 3 1 Connect the fuel connector to the engine and fuel tank 1 Fuel connector 2 Push 3 Insert 1 Pull 2 Insert Hose joint type 3 1 Remove the cap from the fuel joint Connect the fuel hose of the...

Page 40: ...ate to avoid over heating of the engine 2 Run at idling only 3 Remove the propeller See page 81 1 Test tank 2 Water 3 Over 10 cm 4 in ENOW00036 1 Operating outboard motor without cooling water will lead to overheating and damage on the outboard motor severely In case the cooling water check port is not discharging water stop the outboard motor immedi ately check for any object debris which may be ...

Page 41: ...leading to fall down or causing passenger s to be thrown overboard Basic tiller handle type 1 Be sure to install the stop switch lock to the stop switch and attach the stop switch lanyard securely to the operator or to the operator s PFD Personal Flotation Device 1 Stop switch lock 2 Set the shift lever in the Neutral posi tion 1 Shift lever 3 Set the throttle grip to START posi tion 1 Throttle gr...

Page 42: ...witch button and release the button when the engine has started 1 Starter Button Multi function tiller handle type 1 Be sure to install the stop switch lock to the stop switch and attach the stop switch lanyard securely to the operator or to the operator s PFD Personal Flotation Device 1 Stop switch lock 2 Main switch key 2 Insert the main switch key 3 Set the shift lever in the Neutral posi tion ...

Page 43: ...ey returns to the original position auto matically 1 Warning lamp ENOW00032 1 Do not hold turning starter motor more than 5 seconds or the battery may be consumed potentially making the engine starting impossible and or damaging the starter If cranking over 5 seconds fails to start engine return main switch to ON and crank engine again after 10 seconds or more 7 Make sure that water is being dis c...

Page 44: ...trol lever 3 Fully opened Forward 4 Fully opened Reverse 5 Free throttle lever 6 Main switch key 7 Stop switch ENON00035 1 Note The free throttle lever cannot be raised when the control lever is in Forward or Reverse 4 Turn the main switch key to ON posi tion 5 Turn the main switch key to START position and release the key when the engine has started Also confirm warning lamp light up with beep so...

Page 45: ...tely and may lead to accident and personal injury z Be careful that of your clothes or other items do not to get caught in the rotating parts z To prevent accident and injury by rotating parts do not re attach flywheel cover and the top cowl after the engine has been started z Do not pull starter rope if any bystander is around z Attach engine stop switch lanyard to clothing or any part of body su...

Page 46: ...rsonal Flotation Device 7 Set the control lever in the Neutral position 8 Pull the starter handle slowly until you feel engagement keep pulling till you feel less resistance Then pull it quickly 9 Once the outboard motor is started do not reinstall the recoil starter and top cowl ENOM00043 A ENOW00932 1 Be sure to check that cooling water is dis charged from the cooling water check port during war...

Page 47: ...l lever in neutral move the free throttle lever upward to open the throttle 1 Fully open 2 Fully closed ENOM00880 A Trolling speed control If the main switch key for basic tiller han dle model Push switch is pressed for 1 one second during idling or trolling operation engine speed changes each time the main switch key is pressed Engine speed changes as follows Starting 850 min 1 rpm Ѝ 750 min 1 rp...

Page 48: ...rd ENOW00042 1 z Do not shift into Reverse during planing or control will be lost leading to serious personal injury boat may swamp and or hull may be damaged z Do not shift into Reverse during cruising or control may be lost fall down or caus ing passenger s to be thrown overboard Leading to serious personal injury and steering system and or shifting mecha nism may be damaged ENOW00861 1 Do not s...

Page 49: ...he throttle grip is in the fully closed position Multi function tiller type 1 Shift lever 1 Shift lever Forward 1 Turn the throttle grip to reduce engine speed 2 When the engine reaches trolling or idling speed quickly shift the lever into the Forward F position Reverse 1 Turn the throttle grip to reduce engine speed 2 When the engine reaches trolling or idling speed quickly shift the lever into t...

Page 50: ...t 32 where the gear will be connected while lifting up the neutral lock arm located under the control lever grip 2 Further rearward motion will open the throttle Acceleration Open throttle grip or control lever gradu ally 1 Control lever ENOM01904 0 ENOW00868 1 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: ...ey to the OFF position 4 Push the stop switch for a few sec onds to stop the engine 5 Turn the main switch key to the OFF position or push the stop switch Do not forget to turn the key off 1 Throttle grip 2 Shift lever 3 Main switch key Side mount RC type 1 Put the control lever in the Neutral position and run the engine for 2 3 minutes at idling speed for cooling down if it has been running at fu...

Page 52: ...h lock 1 Stop switch 2 Stop switch lock ENOM00910 1 Spare emergency stop switch lock For CE marking model A spare emergency stop switch lock is provided in the accessories bag Make sure that spare stop switch lock is available before operating outboard motor When used as described the emergency stop switch clip and emergency stop switch lanyard system stops the engine if the operator is thrown ove...

Page 53: ...hand or finger in between out board motor body and clamp bracket when adjusting trim angle to prevent pos sible injury z Unsuitable trim position can cause loss of control of boat When testing a trim posi tion run the boat slowly initially to see if it can be controlled safely ENOW00044 1 Excessive trim up or down may cause unsta ble boat operation loss of control that may leads to accident during...

Page 54: ...face during operation ENOM00052 0 Proper trim angle The position of the thrust rod is correct if the hull is horizontal during operation 1 Perpendicular to the water surface ENOM00053 0 Improper trim angle bow rises too high Set the thrust rod lower if the bow of the boat rises above horizontal ENOM00054 0 Improper trim angle bow dips into the water Set the thrust rod higher if the bow of the boat...

Page 55: ...3 Tilt up the outboard motor 4 Lock the tilt stopper 5 Remove the Snap pin and Thrust rod as shown in the picture 1 Snap pin 2 Thrust rod 6 Reinstall the thrust rod in the desired position securely 7 Put the Snap pin back and unlock the tilt stopper 8 Gently tilt down the outboard motor ENOM00060 A ENOW00055 1 Do not tilt the outboard motor up or down when swimmer s and or passenger s are near to ...

Page 56: ...ck lever down until it stops This is the tilt up position Then tilt the outboard motor all the way up until it is locked in place 1 Reverse lock lever 2 Tilt down position 3 Tilt up position ENOM00063 1 Tilt down Pull the reverse lock lever upward until it comes to a stop This is the tilt down position lift up the outboard motor to free it from the reverse lock then release to lower the outboard m...

Page 57: ...and or the power tilt switch is inoperative open the manual valve completely in the Manual direction This allows the outboard motor to be tilted manually ENOW00872 1 Make sure the manual relief valve is closed before operating the outboard motor If the manual relief valve is not closed the out board motor will be tilted up when shifting in reverse ENOW00873 1 Before opening the manual relief valve...

Page 58: ...slow speed and keep the cooling water intake sub merged ENOW00054 1 Do not over tilt the outboard motor when driving in shallow water or air may be sucked through water inlet and sub water inlet potentially leading to engine overheating 1 Water inlet 2 Sub water inlet Manual tilt type 1 Shallow water running position Put the reverse lock lever in the tilt up position and tilt up the outboard motor...

Page 59: ...ly lift up the out board motor and then put it down 1 Reverse lock lever 2 Tilt down position 3 Tilt up position ENOM00069 A Power Tilt type 1 Operate the Power Tilt switch and tilt the outboard motor up into desired shallow water running position 2 3 1 ENOF02526 0 UP DN ENOF00067 2 ENOF02437 0 DN UP ENOF02545 0 UP DN ...

Page 60: ...he bat tery cords from the outboard motor 4 Attach the hoist 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 engine Fuel leakage is a fire or explosion hazard which can cause serious injury or death ENOW00065 1 Close air vent screw on fuel tank befor...

Page 61: ...fuel is completely drained then lay the outboard motor with port side down on the cushion as shown in the drawing ENOM00072 1A ENOW00072 0 Trailering in the tilted position may cause damage to the outboard motor boat etc ENOW00073 A Be sure to disconnect fuel connector except when operating engine Fuel leakage is a fire or explosion hazard which can cause serious injury or death ENOW00068 0 Close ...

Page 62: ... motor beforehand and keep the out board motor in the vertical or on a tran som saver bar Tiller handle type While transporting outboard motor attached to the boat on a trailer properly tighten the steering friction bolt to pre vent the outboard motor from moving page 63 1 Ground clearance should be provided sufficiently 2 Transom saver bar ENOW00067 0 Do not go under outboard motor tilted up even...

Page 63: ...ccident and could lead to severe injury Friction adjustment of the throttle grip can be made with the throttle adjustment screw 1 Throttle friction adjustment screw 2 Decrease 3 Increase 1 Throttle friction adjustment screw 2 Decrease 3 Increase ENOM00075 0 ENOW00074 1C Do not overtighten the remote control throttle friction adjustment screw or it could result in difficult handling of the out boar...

Page 64: ...or could lead to severe personal injury ENOW00075 1 Inappropriate adjustment of trim tab could cause steering difficulty After installing or readjusting trim tab check if steering load is even If straight line cruising can not be achieved adjust the trim tab located under the anti ventilation plate z If the boat veers toward the left direct the trim tab towards A left from rear of boat z If the bo...

Page 65: ...Multi Function Tiller Handle according to the number of spacers After adjusting the angle fully turn the til ler handle to both side and check that there is no problem in operation ENON00022 A Notes z Tighten the screws securely z Periodically make sure that the bolts are not loose z The multi function tiller handle kit includes one spacer 1 one spacer 2 and screws 5 Multi function tiller handle a...

Page 66: ... and maintenance procedures described in this section z 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 com mercial use maintenance should be per formed at shorter intervals If in doubt consult your dealer for advice z...

Page 67: ...s normally and make sure the stop switch lock is secured Remedy or replace if necessary Check cords for loose connections and damage Correct or replace if necessary Check the spark plugs for dirt wear and carbon build up Clean or replace if necessary Check the warning buzzer one beep and warning LED lamp ON for 1 sec when start up Repair Recoil starter Check the rope for wear and chafing Replace i...

Page 68: ...ENON00024 0 Note The oil level should be checked when the engine is cooled ENON00025 0 Note Consult with an authorized dealer if the engine oil is milky color or appears con taminated ENOM00082 A Engine oil replenishing ENOW00079 A z Do not add engine oil of brand and grade other than existing one In case engine oil of other brand or grade is added drain all oil and ask dealer for treatment z In c...

Page 69: ...chemical properties of water on which your out board motor is regularly used If outboard motor is used in salt water brackish water or water with high acidic level use fresh water to remove salt chemicals or mud And flush cooling water passage after every use or before storing outboard motor for long time Before flushing remove the propeller and the forward thrust holder ENOM01903 0 Gear case flus...

Page 70: ...just the flow so that excess water continues leaking out from around the rubber cups to ensure the engine is receiving an adequate supply of cooling water 1 Gear case flushing device 5 Place the shift lever in the neutral position and start the engine and run at idle speed for 3 5 minutes 6 Check if a steady stream of water flows from the cooling water check port 7 Stop the engine and turn off the...

Page 71: ...nector cap 5 Tilt up the outboard motor 1 Flushing connector cap 2 Hose joint ENOM00085 A Flushing by test tank ENOW00081 1 Do not start engine without removing pro peller turning propeller out in the open may lead to personal injury ENOW00082 0 Never start or operate the engine indoors or in any space which is not well ventilated Exhaust gas contains carbon monoxide a colorless and odorless gas w...

Page 72: ... try to determine the cause and respond to the problem as simply replacing the fuse will likely be blown again If you are unable to respond to the cause or the fuse continues to blow request an authorized Tohatsu dealer for inspection 1 Stop the engine and disconnect the battery cable from the battery nega tive terminal 2 Remove the engine cover 3 Remove the fuse box lid 4 Remove the fuse for insp...

Page 73: ...eck Replace if necessary Fuel tank z z Check and clean Fuel tank cap z z Check Replace if necessary Fuel pump Check Replace if necessary Fuel pressure Check Hose z z Check Replace if necessary Ignition System Spark plug z Check and clean Gap 0 8 0 9 mm 0 031 0 035 in Spark plug cap High tension cord Check Replace if necessary Starting System Starter rope z z Wear check Replace if necessary Starter...

Page 74: ...ing Check Replace if necessary Shift Throttle Throttle cable Check Replace if necessary Throttle link Check and adjust Shift cable Check Replace if necessary Shift link Check and adjust Power trim tilt z z Check and replenish Warning system Check Stop switch z z Check Meters Check Bolt nut Retighten Sliding part rotation part z z Apply grease and Pump in grease Grease nipple z z Pump in grease Out...

Page 75: ... 0 Use of engine oils that does not meet these requirements will result in reducing engine life and other engine problems ENOW00933 0 Engine oil mixed with dust or water will dra matically shorten the life of the engine ENOM01906 0 To change engine oil Be sure to use recommended engine oil 1 Stop the engine and leave it in a verti cal position over 5 minutes 2 Put an oil drain pan under the oil dr...

Page 76: ...0 Note Use only recommended engine oil See page 33 ENOW00925 0 Wipe off engine oil well immediately if spilled and dispose of it in accordance with local fire prevention and environment protection regulations ENON00031 0 Notes z If any amount of water is found in engine oil making it milky white consult dealer z If engine oil is contaminated with fuel emitting strong fuel smell consult dealer z So...

Page 77: ... base Apply a film of clean oil to the O ring on the new oil filter Do not use grease 5 Install oil filter and tighten it to speci fied torque by using oil filter wrench Oil filter torque 18 N m 13 ft lb 1 8 kgf m 6 Wipe up any spilled oil Install the oil drip tray plug ENON00028 A Note If a torque wrench is not available when you are fitting an oil filter a good estimate of the correct torque is ...

Page 78: ... damage Fuel filters are provided inside the fuel tank and engine ENOM00094 0 Fuel filter for engine 1 Check the cup for water and debris In case of water entry 1 Prepare a container under the outlet of the fuel filter 2 Loosen the drain screw of the fuel fil ter 3 Squeeze the primer bulb several times After the water is drained stop squeezing 4 Tighten the drain screw securely and confirm there i...

Page 79: ...2 Filter ENOM00098 A Gear oil replacement ENOW00076 1 z Be sure that the outboard motor is secured to transom or service stand or accidental drop or fall of outboard motor could lead to severe personal injury z Be sure to lock the outboard motor in the tilt up position or accidental fall of out board motor could lead to severe per sonal injury z Do not go under outboard motor in the tilt up positi...

Page 80: ...0 mL 15 6 16 2 US Imp oz 4 Install the upper oil plug and then remove oil tube nozzle and install the lower oil plug Oil plug specified tightening torque 4N m 3 ft lb 0 4 kgf m ENOW00095 0 Do not reuse oil plug gasket Always use new gasket and tighten oil plug properly to pre vent entry of water into lower unit ENOW00928 1 If gear oil is spilled wipe off immediately and dispose according to the lo...

Page 81: ...ead bend both end of the pin apart to lock propeller in place A worn out or bent propeller will lower the motor s performance and cause engine trouble 1 Put a piece of wood block between propeller blade and anti ventilation plate to hold propeller 2 Remove the split pin propeller nut and washer 3 Remove the propeller and thrust holder 4 Apply waterproof grease to the pro peller shaft before instal...

Page 82: ...turning it counter clockwise using a 5 8 16 mm socket wrench and handle that are provided in the tool bag 5 Inspect the spark plug Replace the spark plug with wear on electrodes and if the insulators are cracked or chipped 6 Measure the spark plug gap with a wire type feeler gauge The gap should be 0 8 0 9 mm 0 031 0 035 inches If the gap is out of specifica tion replace the spark plug with a new ...

Page 83: ...the gear case cylinder etc When the anode is eroded more than 1 3 of original size replace it ENON00029 1 Notes z Never grease or paint the anode z At each inspection re tighten all the anode attaching bolts Those bolts may loosen if the anodes are corroded 1 Remove fuel filter to access the anode 2 Power tilt model 3 Manual tilt model ENOF02548 0 2 1 2 3 ...

Page 84: ... tank while the tank is kept in a 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 plug hole 1 Oil cap 2 Oil level Recommended oil Use automatic transmission fluid or equivalent Recommended oil is are as shown below ATF Dexron III Air purging from the ...

Page 85: ...INSPECTION AND MAINTENANCE 85 10 ENOM00960 0 Grease point Apply waterproof grease to the parts shown below ENOF02549 0 ...

Page 86: ...fresh water Drain the water completely Wipe off water with a cloth 2 Remove the fuel hose from the out board motor 3 Drain all fuel from the fuel hoses fuel pump fuel filter See page 78 and vapor separator See page 88 and clean these parts Keep in mind that if gasoline is kept in the vapor separator for a long time gum and varnish will be developed causing the float valve to stick restricting the ...

Page 87: ...When adding a fuel stabilizer additive commercially available first fill the fuel tank with fresh 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 stabilizer additive drain the vapor separator See page 88 2 Follow the instructions on the label when adding the fuel stabilizer addi tive 3 After adding the additive le...

Page 88: ...d use a funnel to avoid spilling fuel 5 Loosen the vapor separator drain screw 6 When thoroughly drained re tighten the drain screw securely 7 Check the drained fuel for the pres ence of water or other contaminants If either is present refill the vapor separator with fuel and then drain the fuel again Repeat this procedure until no water or other contaminants are present in the drained fuel 1 Vapo...

Page 89: ... in order to prime the oil pump 6 Fill fuel tank completely 7 Start the engine and warm up the engine for 3 minutes in the NEU TRAL position 8 Run the engine for 5 minutes at the slowest speed 9 Run the engine for 10 minutes at half throttle The oil used for storage inside the engine will be circulated out to assure optimum performance ENOM00105 A ENOW00098 0 Do not attempt to start submerged outb...

Page 90: ...d submerge the lower half of the outboard motor into the water ENOM00107 A ENOW00935 0 Striking the sea bottom or an underwater object may severely damage the outboard motor Follow the procedure below and consult a dealer as soon as possible 1 Stop the engine immediately 2 Check the control system gear case boat transom etc 3 Return to the nearest harbor slowly and carefully 4 Consult a dealer che...

Page 91: ...Power tilt will not operate Warning lamp ON Warning lamp Flash Warning buzzer ON Possible cause Fuel and Lubrication Systems z z Fuel level is low in the tank z z z z z z Fuel system connection is incomplete z z z z z z Fuel system sucks air z z z z z z Fuel pipe is twisted z z z z z z Fuel tank cap vent is closed z z z z z z Fuel filter fuel pump or injector is clogged z z z z z z Performance of ...

Page 92: ...se is blown z z Shift lever neutral N is not proper position z z Start switch or main switch is defective z Starter motor or starter solenoid operation is defective z PTT switch or solenoid is defective z Air is mixed in PTT fluid Engine will not start Engine stalls immediately after starting Defective idling Poor acceleration Engine speed is very high causing high speed ESG to operate Engine spee...

Page 93: ...ective z z z z z z z Anti ventilation plate is damaged z z z z z z z Mismatched propeller z z z z z z z Propeller is damaged or deformed z z z z z Thrust rod position is incorrect z z z Boat is unbalanced by load position z z z z z z z Transom installation height is too high or too low z z z Improper trottle link adjustment Engine will not start Engine stalls immediately after starting Defective i...

Page 94: ... 1 Spark plug 1 NGK DCPR6E Propeller nut split pin 1 Owner s manual 1 Spare stop switch lock 1 Rigging bolt set 2 Bolt M8 X 85mm Manual tilt model 4 Washer M8 2 Nylon locking nut M8 4 Bolt M12 P1 25 X 105mm Power tilt model 4 Washer 13 34 3 4 Washer M12 4 Nylon locking nut M12P1 25 Cable joint set 2 Cable joint E and ET model 2 Washer 8 5 18 1 6 2 Snap pin Items Remote control fitting assy 1 Drag ...

Page 95: ...ttle while cruising is within the recommended range 25 5000 6000 min 1 rpm 30 5500 6500 min 1 rpm Propeller Mark Propeller Size Diameter pitch inch mm Light boats 14 9 9 14 2 252 360 9 9 x 13 9 6 13 244 330 9 9 x 12 9 8 12 249 305 9 9 x 11 9 8 11 249 279 9 9 x 10 9 72 10 247 254 9 9 x 9 9 72 9 247 229 Heavy boats F8 1 4 10 2 8 3 260 210 ...

Page 96: ...has several sensors to deter mine how much fuel is needed for injec tion under all operating conditions ENOM01003 0 Clean Air Acts of the United States and California and Environment Canada EPA California and Canadian regulations require all manufacturers to provide writ ten instructions that describe the opera tion and maintenance of commercial emission control systems The following instructions ...

Page 97: ...ine parts constitute replacement parts man ufactured to the same high standards as the original parts thus guaranteeing uninterrupted high performance of your outboard motor The use of replacement parts other than Tohatsu Genuine parts could jeopardize the effectiveness of the emission control system Tohatsu as a manufacturer of aftermar ket parts assumes the responsibility that replacement parts ...

Page 98: ...ice prevents overtightening z The fuel tank has a manual vent screw which should be closed for transporta tion and full open for operation and cap removal Since sealed fuel tanks are not openly vented they will expand and contract as the fuel expands and contracts during heating and cooling cycles of the outside air This is normal ENOM00036 0 EQUIPPED FOR UNITED STATES AND CANADA MODEL TOHATSU ado...

Page 99: ...ard s Personal Watercraft and Outboard marine engine 2001 exhaust emission standards Engines meeting these standards have 75 lower emissions than conventional carbureted two stroke engines These engines are equivalent to the U S EPA s 2006 standards for marine engines ENOM01010 0 Two Stars Very Low Emission The two star label identifies engines that meet the Air Resources Board s Personal Watercra...

Page 100: ...ission engines ENOM01012 0 Four Stars Super Ultra Low Emission The four star label identifies engines that meet the Air Resources Board s Stern drive and Inboard marine engine 2009 exhaust emission standards Personal Watercraft and Outboard marine engines may also comply with these standards Engines meeting these standards have 90 lower emissions than One Star Low Emission engines ENOF01004 0 ...

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Page 102: ...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 MFS 25D MFS 30D ...

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TOHATSU MFS 25d, Owner'S Manual

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