TOHATSU M 40 Owner's manual

TOHATSU

OUTBOARDS

of this manual may be reproduced or transmitted in any form or by

any means without the express written permission of Tohatsu

Corporation.

TOHATSU M40D 0 M50D

OWNER REGISTRATION AND INDENTIFICATION

Upon purchasing this product, be sure your dealer fills out the WARRANTY

CARD correctly and mails it to the distributor, completely filled in. This card

identifies you as the legal owner of the product and serves as your warranty

registratmn of the same.

Warranty

This Tohatsu product is fully guaranteed against defective materials and

workmanship for the period from the date of purchase, provided that the

purchase has been registered m accordance wth the above.

The warranty does not extend to faults arising from incorrect installation or

maltreatment and becomes void if the umt is altered, modlfled or repaired by

any other than the company or service center appointed by Tohatsu.

Please note that the warranty covers only your Tohatsu product. It does not

extend to your boat, trailer, associated equipment or other accessories.

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 engine

cover and cylinder block) in the space below This number will come in handy

in the evenr of theft or to quickly help identify the product type.

Serial Number :

To you the Customer

Thank you for selecting a Tohatsu product. You are now the proud owner of an

excellent outboard engine. which will serve you for many years to come.

We would like to point out that carefree usage can only be assured on the

condition that this manual is read through in its enurely and mamtenance. as

described later in this manual, are followed carefully. Should difficulty arise

with the engine, please check the trouble against the troubleshooting list at the

end of this manual, and if it can not be remedied, contact an authorized Tohatsu

service shop or your dealer.

We hope you will get much enjoyment from this product and wish you good

luck wth your boating adventures.

Tohatsu Corporation

1

NOTICE

HEED ALL WARNINGS AND CAUTIONS AS SET FORTH HEREIN.

THEY HAVE BEEN INCLUDED FOR YOUR SAFETY AND MUST BE

READ CAREFULLY. NEGLIGENCE IN OBSERVING SUCH WARNINGS

AND CAUTIONS COULD RESULT IN SEVERE INJURY OR DEATH.

EMERGENCY STOP SWITCH

A safety switch in the steermg Handle or in the Remote Control Box will cut off

the engine when the safety switch line is pulled out. This line connects to the

wrist of the operator, effectively preventing injuries from the propeller if he

falls overboad. We highly recommend use of the safety switch line. since it can

save the life of the operator if bad things come to worse. However, we would

also like to point out the drawbacks of the switch to the operator. Accidental

activation of the swtch (such as the line being pulled in heavy seas), could

cause passengers to lose their balance, fall overboard, and could result in loss of

power in heavey 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 the operator/driver of the boat, you are responsible for the safety of those

aboard, other crafts around you and that local boating regulations are followed.

As such you should possess thorough knowledge of correct operation of the

boat, its accessories and the engine. Thus. to learn about correct operation and

maintenance of the engine, please read through this manual carefully.

WARNING

It is very difficult for a person standing or floating in the water to take evasive

action should he see a power boat heading in his direction. even at a slow

speed. Therefore, it is strongly recommended that when your boat is in the

immediate vicinity of people in the water, the engine be shifted to neutral and

shut off.

SERIOUS INJURY IS LIKELY IF CONTACT IS MADE WITH A PERSON

IN THE WATER BY A MOVING BOAT, GEAR HOUSING, PROPELLER,

OR ANY SOLID DEVICE RIGIDLY ATTACHED TO A BOAT OR

GEARHOUSING~

2

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 It is also the operator’s responsibihty to return the unit to the local

dealer for periodic inspection.

Correct periodic maintenance and good care of this outboard engine will lessen

the chance for problems and keep overall operating expenses at a minimum.

SERVICING, REPLACEMENT PARTS & LUBRICANT.

Only let an 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. you should have acquanted yourself with

the correct maintenance of the same. Please comply with all instructmns on

lubrication and mamtenance, and return the engine to the dealer for periodic

inspection at the prescribed intervals.

Troublefree operation cannot be expected unless the engine receive correct

periodic maintenance and is taken good care of. Moreover, if such maintenance

is performed periodically, it is not likely that a costly overhaul would ever be

required.

3

CONTENTS

Page

Specifications ..............................................

.6

Nomenclature .............................................. .a

1. Engine Installation on Boat. ...........................

14

I Installation ................................................ .14

2 Stem Bracket Dimentional Drawing ............................ .16

2. Remote Control Box ................................. ..I 8

I Installing the Remote Control Box ............................. .18

2 Connecting the Remote Control Cable to the Remote Control Box 19

3 Connecting the Remote Control Cable to the Engine ................ 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

1 Non Auto-mixing model M40D . M40DEF ..................... .32

M50DEF

2 Auto-mixing model ......................................... -32

M40DEFO. M40DEFTO. M40DEPO - M40DEPTO

M50DEFO - MSODEFTO . M50DEPO. M50DEPTO

4. Running..

............................................ ...3 6

lBreak-in...................................................3 6

2Starting....................................................3 7

3ManualStart................................................4 5

in case of trouble with the Recoil Starter or the Electric Starter Motor

4Warm.up ............................................... ...4 E

5 Overheat Buzzer ........................................... .49

5. Operation ............................................... .so

1 FonvardlReverse Running ................................... .50

2 Shallow Water Running ..................................... .S2

4

3StoppingtheEngine ....................................... ..5 3

6.Trim Adjustment........................................S 7

7. Mooring with the Engine Tilted up ...................

.61

6. Dismounting the Engine from the Boat ............. .65

9. Adjustments ........................................... -67

I Remote Control Lever Load .................................. .67

M40DEPO. M40DEPTO/M50DEPO. M50DEPTO

2 Trim Tab Adjustment ........................................

67

3 Steering Load Adjustment .................................... .68

4 Throttle Grip Turning Load Adjustment ......................... -68

10. Inspection and Maintenance ........................ .69

I Daily Inspection ............................................ .69

2 Periodic Inspection .. ...................................... .73

3ChangingGearOil ........................................ ..7 5

4

Cleaning the Filters .. ...................................... .76

5 Checking and Refilling Oil in the Power Trim &Tilt Unit ........... .77

ll.WinterStorage.........................................7 9

I Engine

2 Battery

3 Electric Starter Mater

12. Pre-season Check ..................................... 80

13. If the Engine Becomes Submerged in Water ....... .82

14. Precautions in Cold Weather ....................... .B2

15. Troubleshooting ..................................... .a2

16. Accessories .......................... .............. .8S

17. Propeller Selection _, ............................ ... -86

18. Optional Accessories ............................... ..8 7

19. Wiring Diagram .......... _, ..... _, .................... .89

5

Max. output, KW(PS)

Full Throttle Speed Range 4OPS 4 500 - 5 500

0 $

0

1)

V

Exhaust System through propeller hub exhaust

Lubrication

Fuel Mixing Ratio

Cooling System

Starting System

Ignition

manual mixing in fuel oil

tank Auto-mixing system

50:l (after completing

break-in)

forced water cooling

recoil hand 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

- t

I

- I

,

Trim Stages 6 5 6 5

Engine oil genuine TOHATSU Engine Oil “SUPER GOLD”

Tohatsu gear oil (API GL5, SAE#SO or #SOW)

Fuel Tank Capacity

Engine Oil Tank Capacity

22.7 liters (6 U.S. gal.)

- 2 liters (0.528 U.S. gal.)

3ear Reduction Rata 13 : 24

M40D

1. Tilt Handle

2. Upper Mo,or cover

3. Hook Lever

4. Water Check Port

5. Tilt Stopper 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

18. Slader Handle

19. Safety Switch

20. Choke knob

21. Reverse locking Lever

22. Anode

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

M40DEFO/M50DEFO

1. lilt Handle

2. Upper Molar Cover

3, Hook Lever

4. Waler 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 Grip @

17. Shin Lever

18. Starter Handle

19. sa,ety switch

20. Choke knob

M40DEFTO/M50DEFTO

1, Till Handle

2. Upper Motor Cover

3. Hook Lever

4 Waer Check Port

5. Till Stopper Lever

5. water 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

19. Safety Switch

20. Choke knob

21. Pilot Lamp

22. Mm Switch

23. Battery Cords

24. Power Trim & Tilt

25. Anode

“, ,,,,,, ,,,i, ,,,,, .,,, 81, ,II\ ,,,

M40DEPO/M50DEPO

1. Tilt Handle

2. Upper Motor Cover

3. Hook Lever

4. Water Check Port

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. Filler Lid

IS. me, connecter

19. Battery cords

20. ReYerSe Locking Lever

21, Anode

M4ODEPTO/MSODEPTO

1. ENGINE INSTALLATION ON BOAT

I

AA

WARNING I

The maximum horsepower rating of the engine is indicated on the

CERTIFICATION PLATE on the engine itself. Be sure that the

maximum engine horsepower rating does not exceed that

recommended for your boat. It is very DANGEROUS to operate a

boat with an overpowered engine.

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 engine at the

exact center of the stern, and mount

it using a cushioning pad or plate.

(Fig. 1)

@Twin-engine Installation

W Position thk outboard engines 470-

660mm (I 8.5 - 26.0 in.) apart.

measured from an imagined center

line of each engine, in the exact

center of the stern. (Fig. 2)

I .I~

w

1

c &

A- A-

(Fig. 1)

470 - 680mm

m3.0 in.)

(Fig. 2)

14

@Transom Height

Install the

engine with the Anti-cavitation Plate at a level 0 - 30mm (0 -

I. I8 in.) below the bottom of the boat. (Fig. 3)

b/

(Fig. 3)

I A

CAUTION I

I

Overheating may occur if the Anti-cavitation Plate is at a level higher than the

bottom of the boat, as a result of air sucking. I

W If the hight difference 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 Bracket, fix it with clamp screws then drill four

holes in the transom board, matching the holes in the Stern Bracket. Secure

the engine with the supplied bolts (Ml2 x 90mm) and nuts Be sure to use

the washers The small diameter washers go with the bolts and the larger

diameter washers go wit the nuts

15

The mounting holes may be drilled beforehand by referring 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 M40DEFTO - M40DEPTO

M50DEFTO - M50DEPTO

(12mm x lenglh 90mm)

16

NOTE

We recommend that the bolt head

of

the upper bolts face inward 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 the bolt.

2. Be sure to fti the engine securely with the bolts.

17

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