TOHATSU M 2.5A2, M 3.5B2, M 3.5A2 Owner's Manual
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OWNER’S
MANUAL
M 2.5A
M 3.5A
M 3.5B
OB No.003-11045-7AF1
2
2
2
ENOM00001-0
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 © 2016 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.
YOUR TOHATSU OUTBOARD MOTOR
ENOM00006-A
To You, Our Customer
Thank you for selecting a TOHATSU outboard motor. You are now the proud owner of an
excellent outboard motor that will service you for many years to come.
This manual should be read in its entirety and the inspection and maintenance procedures
described later in this manual should be followed carefully. Should a problem arise with the
outboard motor, please follow the troubleshooting procedures listed at the end of this
manual. If the problem persists, contact an authorized TOHATSU service shop or dealer.
Please always keep this manual together with the outboard motor as a reference to everyone who uses the outboard motor. If the outboard motor is resold, make sure the manual
is passed on to the next owner.
We hope you will enjoy your outboard motor and wish you good luck in your boating
adventures.
TOHATSU CORPORATION
ENOM00003-0
PRE-DELIVERY CHECK
Be sure that the product has been checked by an authorized TOHATSU dealer before you
take delivery.
3
4
ENOF02000-0
ENOF02001-0
ENOM00005-B
Serial Number
In the space below, please record the outboard motor's serial number (indicated both on
the swivel bracket and on the cylinder block). The serial number will be needed when
ordering parts, and when making technical or warranty inquiries.
Serial Number:
Serial Number: Date of purchase:
ENOM00007-0
NOTICE: DANGER/WARNING/CAUTION/Note
Before installing, operating or otherwise handling your outboard motor, be sure to thoroughly read and understand this Owner's Manual and carefully follow all of the instructions. Of particular importance is information preceded by the words “DANGER,”
“WARNING,” “CAUTION,” and “Note.” Always pay special attention to such information to
ensure safe operation of the outboard motor at all times.
ENOW00001-0
DANGER
Failure to observe will result in severe personal injury or death, and possibly property damage.
ENOW00002-0
WARNING
Failure to observe could result in severe personal injury or death, or property damage.
ENOW00003-0
CAUTION
Failure to observe could result in personal injury or property damage.
ENON00001-0
Note
This instruction provides special information to facilitate the use or maintenance of the outboard
motor or to clarify important points.
5
CONTENTS
1. GENERAL SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3. PARTS NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4. LABEL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1. Mounting the outboard motor on boat . . . . . . . . . . . . . . . . . . . . . . . . . . .17
6. PRE-OPERATING PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1. Fuel handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2. Engine oil recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3. Fuel filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4. Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7. ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1. Fuel feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2. Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
3. Warming up the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
4. Forward, reverse, and acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5. Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
6. Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
7. Trim angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
8. Tilt up and down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
8. REMOVING AND CARRYING THE OUTBOARD MOTOR. . . . . . . . . . . . . .36
1. Removing the outboard motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
2. Carrying the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
3. Traillering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9. ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
1. Steering friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
10. INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1. Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2. Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
3. Off-season storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
4. Pre-season check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5. Submerged outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
6. Cold weather precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
7. Striking underwater object. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
8. Auxiliary outboard motor operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
11. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
12. TOOL KIT AND SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
13. PROPELLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
INDEX
9
1 GENERAL SAFETY INFORMATION
2. SPECIFICATIONS
3. PARTS NAME
4. LABEL LOCATIONS
5. INSTALLATION
6. PRE-OPERATING PREPARATIONS
7. ENGINE OPERATION
8. REMOVING AND CARRYING THE
OUTBOARD MOTOR
9. ADJUSTMENT
1
2
3
4
5
6
7
8
9
10.INSPECTION AND MAINTENANCE
11.TROUBLESHOOTING
12.TOOL KIT AND SPARE PARTS
13.PROPELLER TABLE
10
11
12
13
14
14
10
GENERAL SAFETY INFORMATION
ENOM00009-0
SAFE OPERATION OF BOAT
1
As the operator/driver of the boat, you are responsible for the safety of those aboard and
those in other boat around yours, and for following local boating regulations. You should
be thoroughly knowledgeable on how to correctly operate the boat, outboard motor, and
accessories. To learn about the correct operation and maintenance of the outboard motor,
please read through this manual carefully.
It is very difficult for a person standing or floating in the water to take evasive action should
he or she see a power boat heading in his/her direction, even at a slow speed. Therefore,
when your boat is in the immediate vicinity of people in the water, the outboard motor
should be shifted to neutral and shut off.
ENOW00005-0
WARNING
SERIOUS INJURY IS LIKELY IF A PERSON IN THE WATER MAKES CONTACT WITH A MOVING BOAT, GEAR HOUSING, PROPELLER, OR ANY SOLID DEVICE RIGIDLY ATTACHED TO
A BOAT OR GEAR HOUSING.
ENOM0008-A
EMERGENCY STOP SWITCH
The Emergency Stop Switch will stall the outboard motor when the stop switch lanyard is
pulled off. This stop switch lanyard has to be attached to the operator of the outboard
motor to minimize or prevent injuries from the propeller in case the operator falls overboard.
It is operator’s responsibility to use the Emergency Stop Switch Lanyard.
ENOW00004-A
WARNING
Accidental activation of the Emergency Stop Switch (such as the tether being pulled out in
heavy seas) could cause passengers to lose their balance and even fall overboard, or it
could result in loss of power in heavy seas, strong currents, or high winds. Loss of control
while mooring is another potential hazard.
To minimize accidental activation of the Emergency Stop Switch, the 500 mm (20 inch.) stop
switch lanyard is coiled and can extended to a full 1300 mm (51 inch.).
ENOM00800-A
PERSONAL FLOATATION DEVICE
As the operator/driver and passenger of the boat, you are responsible to wear a PFD (Personal Floatation Device) while on the boat.
GENERAL SAFETY INFORMATION 11
ENOM00010-0
SERVICING, REPLACEMENT PARTS & LUBRICANTS
We recommend that only an authorized service shop perform service or maintenance on
this outboard motor. Be sure to use genuine parts, genuine lubricants, or recommended
lubricants.
ENOM00011-A
MAINTENANCE
As the owner of this outboard motor, you should be acquainted with correct maintenance
procedures following maintenance section of this manual (See page 40). 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. 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 intervals.
Correct periodic maintenance and proper care of this outboard motor will reduce the
chance of problems and limit overall operating expenses.
Carbon Monoxide Poisoning Hazard
Exhaust gas contains carbon monoxide, a colorless and odorless gas which can be fatal if
inhaled for any length of time.
Never start or operate the engine indoors or in any space which is not well ventilated.
Gasoline
Gasoline and its vapors are very flammable and can be explosive. Use extreme care when
handling gasoline. You should be thoroughly knowledgeable on how to correctly handle
gasoline by reading this manual.
1
12
SPECIFICATIONS
ENOM00810-B
MODEL FEATURE
Model M2.5A2 M3.5A2 M3.5B2
2
Ty pe MF MF MF
Transom heights
Tiller Handle z z z
Remote Control
Separate fuel tank
Integral fuel tank z z z
Shifting z
Manual tilt z z z
*1: Option
ENOM00811-B
MODEL NAME EXAMPLE
M3.5B2S
S z z z
L z z z
UL
M 3.5 B 2 S
Model description Horse power
M (X)= Two stroke
F= Four stroke
D= Two stroke DI
- A and up 2 and up
Product genera-
tion
Minor change Shaft length
S= Short 15 in
L= Long 20 in
UL= Ultra long 25 in
ENOM01300-0
2.5A2, 3.5A2, 3.5B2
SPECIFICATIONS 13
Item MODEL
Overall Length mm (in) 550 (21.7)
Overall Width mm (in) 345 (13.6) 220 (8.7)
Overall Height
Transom Height
Weight
Output kW (ps) 1.8 (2.5) 2.6 (3.5)
Max. Operating Range rpm 3,800-5,200 4,200-5,300
Trolling Speed in Forward Gear
Idle Speed in Neutral Gear rpm - 1,300
Engine Type 2-Stroke
Number of Cylinders 1
Bore x Stroke mm (in) 47 x 43 (1.85 x 1.69)
Piston Displacement mL (Cu in) 74.6 (4.55)
Exhaust System Underwater exhaust
Cooling System Forced water cooling
Lubrication System Engine Oil Mixed Gasoline
Starting System Manual starter
Ignition System Flywheel Magneto C.D. Ignition
Spark Plugs NGK BP6HS-10/BPR6HS-10
Trim Position 4
Fuel
Fuel Tank Capacity L (US gal) Approx. 1.4 (0.37) integral tank
Engine Oil Genuine motor oil or recommended one (TCW-III)
Fuel : Engine Oil Mixing Retio Unleaded Gasoline 50 : Genuine 2-stroke Engine Oil 1
Gear Oil
Gear Shift Foward F-N
Gear Reduction Ratio 1.85 (13 : 24) 2.15 (13 : 28)
Remark: Specifications subject to change without notice.
Tohatsu outboard is power rated in accordance with ISO8655 (propeller shaft output).
S mm (in) 958 (37.7)
L mm (in) 1085 (42.7)
S mm (in) 435 (17.1)
L mm (in) 562 (22.1)
S kg (lb) 12.5 (28) 13.0 (29)
L kg (lb) 13.0 (29) 13.5 (30)
rpm 1,100
2.5A2 3.5A2 3.5B2
Unleaded regular gasoline : Pump posted 87 Octane
(research octane rating of 91)
Genuine Gear Oil or API GL5, SAE #80 to #90,
approx. 3.5B2:180mL (6.1 fl.oz), 3.5A2 & 2.5A2:90mL (3.0 fl.oz),
2
14
1
2
3
9
10
20
21
18
17
16
15
12
14
13
22
11
24
19
4
5
7
8
23
25
27
26
28
30
29
6
ENOF02002-0
PARTS NAME
ENOM01301-0
2.5A2, 3.5A2, 3.5B2
3
1 Air Vent Screw
2 Fuel Tank Cap
3 Top Co wl
4 Plug Cap Cover
5 Fuel Cock
6 Cooling Warter Check Port
7 Clamp Bracket
8 Drive Shaft housing
9 Propeller
10 Water Inlet (2.5/3.5A2)
11 Starter Handle
12 Shift Lever(3.5B2 only)
13 Handle Grip
14 Carring Handle
15 Clamp Screw
16 Thrust Rod
17 Oil Plug (Upper)
18 Anti-Ventilation Plate
19 Water Inlet (3.5B2 only)
20 Gear Case
21 Oil Plug (Lower)
22 Throttle Lever
23
24
Tilt Stopper
Stop Switch
25
Carburetor Cover
26
Chork Lever
27
Drive Shaft Housing
Grommet (3.5B2 only)
28
Steering Adjustment Screw
29
Spark Plug
30
Fuel Filter
LABEL LOCATIONS
ENOF02050-0
3C8-72181-0B
ENOM00019-A
Warning label locations
15
1
1.
Warning label regarding owner’s manual, top cowl, engine stop switch.
2
3
4
4
ENOF02003-0
3.
Warning label regarding Emergency
manual starting procedure (3.5B2 only)
(See page 27)
3C7-72180-3
2. Warning regarding fuel tank cap. (See
page19, 24)
4.
Warning regarding high voltage.
ENOF00005-Z
LABEL LOCATIONS16
ENOM01001-0
Serial number label locations
aR
:ssaM
4
1. Model code(Model name)
2. Rated power
3. Dry mass weight
4. Serial No.
5. Manufacture name
6. Manufacture address
S
rotoM draobtuO
1)
:rewoP det
2)
3)
4)
.oN laire
5)
6)
7)
napaJ
i
n
aM
ed
ENOF02048-0
INSTALLATION
17
ENOM00024-B
1. Mounting the outboard motor on
boat
ENOW00006-0
WARNING
Most boats are rated and certified in terms
of their maximum allowable horsepower,
as shown on the boat’s certification plate.
Do not equip your boat with an outboard
motor that exceeds this limit. If in doubt,
contact your dealer.
Do not operate the outboard motor until it
has been securely mounted on the boat in
accordance with the instructions below.
ENOW00009-0
WARNING
z Mounting the outboard motor 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
bolts can lead to the release or displacement of the outboard motor, possibly
resulting in lost of control and/or serious
personal injury. Be sure that fasteners
are tightened to the specified torque (30
Nm (3.0 kgf) 13 ft-lb). Check the fasteners for tightness from time to time.
z Be sure to use outboard mounting fas-
teners included in the outboard motor
package or their equivalents in terms of
size, material, quality and strength.
Tighten fasteners to the specified torque
(30 Nm (3.0 kgf) 13 ft-lb). Test cruise to
check if fasteners are tightened
securely.
z Outboard motor mounting must be per-
formed by trained service person(s)
using lift or hoist with sufficient capacity.
Keep the outboard motor in a vertical position when mounting.
ENOF02004-0
2
1. Clamp Screw
2. Tighten
ENOM00025-0
1
ENOF02005-0
Position ... Above keel line
Set engine at center of boat.
1
2
1. Center of boat
ENOF01141-0
5
INSTALLATION18
1
2
30−50 mm
(1.2−2 in)
ENOF01608-0
2. Boat transom
ENOM00026-0
Transom matching
Be sure that the anti ventilation plate of the
outboard motor is 30–50 mm (1.2–2 in)
below the bottom of hull.
If the above condition cannot be met due
to the shape of the bottom of your boat,
please consult your authorized dealer.
5
1. Bottom of hull
2. Anti ventilation plate
ENOW00007-0
CAUTION
z Before beginning the running test, check
that the boat with maximum capacity
loading floats on the water in a proper
attitude. Check the position of water
surface on the driveshaft housing. If the
water surface is near the bottom cowling, in high waves, water may enter the
engine cylinders.
z Incorrect outboard motor mounting
height or existence of underwater
object(s), such as hull bottom design,
bottom surface conditions or underwater accessories, can cause water spray
possibly reaching the engine through an
opening of the bottom cowling during
cruising. Exposing the engine to such
conditions for extended periods can
lead to severe engine damage.
ENOM00830-A
Mounting bolts
Manual tilt type
1. To attach the outboard motor to the
boat, tighten the clamp screws by
turning their handles.
Also, use the bolts to secure the outboard motor brackets on transom
board.
Secure the outboard motor with a rope
to prevent loss overboard.
ENON00002-0
Note
A rope is not included in the standard
accessories.
ENOF02006-0
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