TOHATSU M 25H, M 30H, M 40C Owner's Manual

OWNER’S

MANUAL

M 25H

30H 40C

OB No.003-11055-5

READ THIS MANUA L BEFO RE USI NG TH E OUTB OARD MOTOR. FAILUR E TO FO LLOW THE

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INS TRUC TIO NS A ND S AFE TY P RECA UTI ONS IN THI S MA NUA L CA N RE SULT IN SER IOU INJURY OR DEATH. KEEP THIS MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE.

reproduced or transmitted in any from or by any means without the express written

be permission of Tohatsu Corporation.

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YOUR TOHATSU OUTBOARD MOTOR

OWNER REGISTRATION AND IDENTIFICATION

Upon purchasing this product, be sure that the WARRANTY CARD is correctly and completely ﬁlled out and mailed to the addressee noted there on. This WARRANTY CARD identiﬁes you as the legal owner of the product and serves as your warranty registration.

TO THE EXTENT PERMITTED BY APPLICABLE LAW, YOUR OUTBOARD MOTOR WILL NOT BE COVERED BY THE APPLICABLE LIMITED WARRANTY, IF THIS PROCEDURE IS NOT FOLLOWED.

PRE-DELIVERY CHECK

Be sure that the product has been checked by an authorized TOHATSU dealer before you take delivery.

Limited Warranty

Please refer to the TOHATSU outboard motor Limited warranty provided to you with this product, the terms and conditions of which, as amended from time to time, are incorporated by reference into the manual.

Serial Number

In the space below, please record the outboard motor's serial number (indicated both on the bottom cowl and on the cylinder block). The serial number will be needed in the event of theft or to quickly identifying the outboard motor type.

Serial Number :

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.

We hope you will enjoy your outboard motor and wish you good luck in your boating adventures.

TOHATSU CORPORATION

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.

Failure to observe will result in severe personal injury or death, and possibly property damage.

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Failure to observe could result in severe personal injury or death, or property damage.

Failure to observe could result in personal injury or property damage.

Note

This instruction provides special information to facilitate the use or maintenance of the outboard motor or to clarify important points.

EMERGENCY STOP SWITCH

The Emergency Stop Switch will stall the outboard motor when the stop switch tether is pulled off. This stop switch tether can be attached to the operator of the outboard motor to minimize or prevent injuries from the propeller in case the operator falls overboard. We highly recommend use of the Emergency Stop Switch tether.

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 tether is coiled and can extended to a full 1,300 mm (51 inch.).

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SAFE OPERATION OF BOAT

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.

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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.

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.

MAINTENANCE

As the owner of this outboard motor, you should be acquainted with correct maintenance procedures. 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.

MOUNTING

Outboard motor mounting must be performed by trained service person(s) using lift or hoist with sufﬁcient capacity.

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SPECIFICATIONS

25H, 25H EF, 25H EP

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MODEL

Item

Overall Length mm (in) 884 (34.8) 600 (23.6)

Overall Width mm (in) 412 (16.2) 355 (14.0)

Overall Height S·L·UL mm (in) 1,124 (44.3) · 1,251 (49.3) · 1,378 (54.3)

Transom Height S·L·UL mm (in) 435 (17.1) · 562 (22.1) · 689 (27.1)

S kg (lb) 51 (112) 55 (121) 54 (119)

Weight

Output kW (Hp) 18.4 (25)

Max. Operating Range rpm 5,000-6,000

Number of Cylinder 2

Piston Displacement mL (Cu in) 429 (26.16)

Bore X Stroke mm (in) 68 X 59 (2.68 X 2.32)

Exhaust System Through hub exhaust

Lubrication System Engine Oil Mixed Gasoline

Cooling System Forced water cooling

Starting System Manual Electric starter motor*

Ignition System Flywheel Magneto C.D. Ignition

Spark Plug NGK B7HS-10/BR7HS-10

Alternator 12V, 80W (Max.)

Trim Position 6

Engine Oil Mixing Ratio Unleaded Gasoline 50 : Genuine 2-stroke Engine Oil 1

Gear Oil mL (ﬂ.oz.)

Fuel Tank Capacity L (US gal) 25 (6.6)

Gear Reduction Ratio 1.92 (12 : 23)

* : with manual Remark :

Speciﬁcations subject to change without notice.

L kg (lb) 52.5 (116) 56.5 (125) 55.5 (122)

UL kg (lb) 54 (119) 58 (128) 57 (126)

25H 25H EF 25H EP

Genuine Gear Oil or API GL5,

SAE #80 - #90, Approx. 280 (9.5)

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30H, 30H EF, 30H EP

SPECIFICATIONS

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MODEL

Item

Overall Length mm (in) 884 (34.8) 600 (23.6)

Overall Width mm (in) 412 (16.2) 355 (14.0)

Overall Height S·L·UL mm (in) 1,124 (44.3) · 1,251 (49.3) · 1,378 (54.3)

Transom Height S·L·UL mm (in) 435 (17.1) · 562 (22.1) · 689 (27.1)

S kg (lb) 51 (112) 55 (121) 54 (119)

Weight

Output kW (Hp) 22.1 (30)

Max. Operating Range rpm 5,150-5,850

Number of Cylinder 2

Piston Displacement mL (Cu in) 429 (26.16)

Bore X Stroke mm (in) 68 X 59 (2.68 X 2.32)

Exhaust System Through hub exhaust

Lubrication System Engine Oil Mixed Gasoline

Cooling System Forced water cooling

Starting System Manual Electric starter motor*

Ignition System Flywheel Magneto C.D. Ignition

Spark Plug NGK B7HS-10/BR7HS-10

Alternator 12V, 80W (Max.)

Trim Position 6

Engine Oil Mixing Ratio Unleaded Gasoline 50 : Genuine 2-stroke Engine Oil 1

Gear Oil mL (ﬂ.oz.)

Fuel Tank Capacity L (US gal) 25 (6.6)

Gear Reduction Ratio 1.92 (12 : 23)

* : with manual Remark :

Speciﬁcations subject to change without notice.

L kg (lb) 52.5 (116) 56.5 (125) 55.5 (122)

UL kg (lb) 54 (119) 58 (128) 57 (126)

30H 30H EF 30H EP

Genuine Gear Oil or API GL5,

SAE #80 - #90, Approx. 280 (9.5)

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SPECIFICATIONS

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40C 40C EF, 40C EP

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MODEL

Item

Overall Length mm (in) 919 (36.2) 600 (23.6)

Overall Width mm (in) 415 (16.3) 355 (14.0)

Overall Height S·L·UL mm (in) 1,118 (44.0) · 1,245 (49.0) · 1,372 (54.0)

Transom Height S·L·UL mm (in) 435 (17.1) · 562 (22.1) · 689 (27.1)

S kg (lb) 59 (130) 62 (137) 60.5 (133)

Weight

Output kW (Hp) 29.4 (40)

Max. Operating Range rpm 5,200-5,800

Number of Cylinder 2

Piston Displacement mL (Cu in) 493 (30.08)

Bore X Stroke mm (in) 70 X 64 (2.76 X 2.52)

Exhaust System Through hub exhaust

Lubrication System Engine Oil Mixed Gasoline

Cooling System Forced water cooling

Starting System Manual Electric starter motor*

Ignition System Flywheel Magneto C.D. Ignition

Spark Plug NGK B7HS-10/BR7HS-10

Alternator 12V, 80W (Max.)

Trim Position 6

Engine Oil Mixing Ratio Unleaded Gasoline 50 : Genuine 2-stroke Engine Oil 1

Gear Oil mL (ﬂ.oz.)

Fuel Tank Capacity L (US gal) 25 (6.6)

Gear Reduction Ratio 1.92 (13 : 25)

* : with manual Remark :

Speciﬁcations subject to change without notice.

L kg (lb) 60.5 (133) 63.5 (140) 62 (137)

UL kg (lb) 62 (137) 65 (143) 63.5 (140)

40C 40C EF 40C EP

Genuine Gear Oil or API GL5,

SAE #80 - #90, Approx. 420 (14.3)

NAMES OF PARTS

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6 7

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9 0

p

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y

t

r

w

q

a

s

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l

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j

k

25H, 30H

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3

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1

Tilt Handle

2

Top Cowl

3

Cooling Water Check Port

4

Water Plug

5

Reverse Lock Lever

6

Anti Ventilation Plate

7

Trim Tab

8

Sub Water Inlet

9

Water Inlet

0

Propeller

q

Oil Plug (Lower)

w

Oil Plug (Upper)

e

Drive Shaft Housing

r

Thrust Rod

t

Clamp Bracket

y

Clamp Screw

u

i

o

p

Throttle Grip Adjust Nut Shift Lever Starter Handle

a

Stop Switch

s

Choke Knob

d

Fuel Connector

f

Primer Bulb

g

Fuel Connector

h

Fuel Tank Cap

j

Air Vent Screw

k

Fuel Pick up Elbow

l

Fuel Tank

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s

d

f

a

h

j

k

l

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e

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2

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9 0

p

o

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y

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r

w

q

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z

NAMES OF PARTS

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25H EF, 30H EF

1

Tilt Handle

2

Top Cowl

3

Cooling Water Check Port

4

Water Plug

5

Reverse Lock Lever

6

Anti Ventilation Plate

7

Trim Tab

8

Sub Water Inlet

9

Water Inlet

0

Propeller

q

Oil Plug (Lower)

w

Oil Plug (Upper)

e

Drive Shaft Housing

r

Thrust Rod

t

Clamp Bracket

y

Clamp Screw

u

Throttle Grip

i

Adjust Nut

o

p

a

s

Shift Lever Starter Handle Battery Cable Stop Switch

d

Choke Knob

f

Main Switch

g

Fuel Connector

h

Primer Bulb

j

Fuel Connector

k

Fuel Tank Cap

l

Air Vent Screw

;

Fuel Pick up Elbow

z

Fuel Tank

25H EP, 30H EP

j

k

l

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e

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2

3

4

5

6 7

8

9 0

i

u

y

t

r

w

q

f

g

h

o

p

a

s

d

NAMES OF PARTS

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2

1

Tilt Handle

2

Top Cowl

3

Cooling Water Check Port

4

Water Plug

5

Reverse Lock Lever

6

Anti Ventilation Plate

7

Trim Tab

8

Sub Water Inlet

9

Water Inlet

0

Propeller

q

Oil Plug (Lower)

w

Oil Plug (Upper)

e

Drive Shaft Housing

r

Thrust Rod

t

Clamp Bracket

y

Clamp Screw

u

Shift Lever

i

Starter Handle

o

Battery Cable

p

Fuel Connector

a

Primer Bulb

s

Fuel Connector

d

Fuel Tank Cap

f

Air Vent Screw

g

Fuel Pick up Elbow

h

Fuel Tank

j

Remote Control

k

Main Switch

l

Stop Switch

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Cord Assembly

2

o

i

u

y

t

r

e

q

8

0

w

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2

3

4

5

6

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9

p

a

s

k

d

f

g

h

j

NAMES OF PARTS

16

40C

1

Tilt Handle

2

Top Cowl

3

Cooling Water Check Port

4

Water Plug

5

Reverse Lock Lever

6

Anti Ventilation Plate

7

Trim Tab

8

Water Inlet

9

Propeller

0

Oil Plug (Lower)

q

Oil Plug (Upper)

w

Drive Shaft Housing

e

Thrust Rod

r

Clamp Bracket

t

Clamp Screw

y

Throttle Grip

u

Adjust Nut

i

Shift Lever

o

Starter Handle

p

Stop Switch

a

Choke Knob

s

Fuel Connector

d

Primer Bulb

f

Fuel Connector

g

Fuel Tank Cap

h

Air Vent Screw

j

Fuel Pick up Elbow

k

Fuel Tank

w

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2

3

4

5

6

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o

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t

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q

0

d

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g

h

j

k

l

40C EF

NAMES OF PARTS

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2

1

Tilt Handle

2

Top Cowl

3

Cooling Water Check Port

4

Water Plug

5

Reverse Lock Lever

6

Anti Ventilation Plate

7

Trim Tab

8

Water Inlet

9

Propeller

0

Oil Plug (Lower)

q

Oil Plug (Upper)

w

Drive Shaft Housing

e

Thrust Rod

r

Clamp Bracket

t

Clamp Screw

y

Throttle Grip

u

Adjust Nut

i

Shift Lever

o

Starter Handle

p

Battery Cable

a

Stop Switch

s

Choke Knob

d

Main Switch

f

Fuel Connector

g

Primer Bulb

h

Fuel Connector

j

Fuel Tank Cap

k

Air Vent Screw

l

Fuel Pick up Elbow

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Fuel Tank

2

u

y

t

r e

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8

q

0

w

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g

p

a

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d

f

h

j

k

l

NAMES OF PARTS

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40C EP

1

Tilt Handle

2

Top Cowl

3

Cooling Water Check Port

4

Water Plug

5

Reverse Lock Lever

6

Anti Ventilation Plate

7

Trim Tab

8

Water Inlet

9

Propeller

0

Oil Plug (Lower)

q

Oil Plug (Upper)

w

Drive Shaft Housing

e

Thrust Rod

r

Clamp Bracket

t

Clamp Screw

y

Shift Lever

u

Starter Handle

i

Battery Cable

o

Fuel Connector

p

Primer Bulb

a

Fuel Connector

s

Fuel Tank Cap

d

Air Vent Screw

f

Fuel Pick up Elbow

g

Fuel Tank

h

Remote Control

j

Main Switch

k

Stop Switch

l

Cord Assembly

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INSTALLATION

Boat Transom

Center of Boat

Bottom of hull

Anti Ventilation Plate

30-50 mm (1.2-2 in)

Approx.580 mm (22.8 in)

Bolt

Clamp screw

Nut & Washer

*option

Washer

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1.

Mounting the outboard motor on boat

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.

Single-engine Installation

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Set engine at center of boat.

Twin-engine Installation

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W h e n i n st a l l i n g t w o o u tb o a r d engines, be sure to keep an interval of approximately 580 mm (22.8 in) between the two.

Transom matching

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Be sure that the anti ventilation plate of the outboard motor is 30-50mm (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.

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To attach the outboard motor to the boat, tighten the clamp screws by turning their handles.

Al s o , us e th e b o lt s t o s e cu r e

the outboard motor brackets on transom board.

Secure the outboard motor with a

rope to prevent loss overboard.

Note

A rope is not included in the standard accessories.

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INSTALLATION

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• 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.

• Incorrect outboard motor mounting height or existence of under water 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.

Mounting bolts should be installed with the bolt head at inside surface of the transom. Mounting bolts installed with the threaded end at the inside surface of the transom can cause personal injury.

• Mounting the outboard motor without following this manual can lead to unsafe conditions such as poor maneuverability, lack of control or ﬁre.

• 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 (3.0kgf) 13ft·lb). Check the fasteners for tightness from time to time.

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Be sure to use outboard mounting fasteners 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 (3.0kgf) 13ft·lb). Test cruise to check if fasteners are tightened securely.

•

Outboard motor mounting must be performed by trained service person(s) using lift or hoist with sufﬁcient capacity.

Notes

1. Apply sealing agent, such as silicone sealed between the bolts and the transom board holes before tightening the bolts.

2. Be sure to tighten the mounting bolt nuts to the speciﬁed torque.

(30 Nm (3.0kgf)13ft · lb)

INSTALLATION

Ball holder

Holder cap

Spring

Washer

Nut

Cable outer groove

Throttle cable

Spring

Nut

Cable outer groove

Shift cableSpring pin

Lock pin

Sleeve B guide

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2.

Installing the remote control devices

It is recommended that you consult wi t h yo u r au t h o r i z e d de a l er fo r installation adjustment of the remote control device.

When using other than Tohatsu’s genuine remote control box, DO NOT select the one without neutral safety switch that prevents in-gear start. Use of remote control box without neutral safety switch can allow start of engine with gear at other than neutral shift, potentially leading passengers to falling or causing passenger to be thrown overboard.

Installation of the Remote Control

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Cables (Box side) :

Fol l o w th e i n st r u cti o n ma n u al

provided with the remote control.

Installation of the Remote Control

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on your boat :

Fol l o w th e i n st r u cti o n ma n u al

provided with the remote control.

25H EP/30H EP

1

Fitting of holder cap and sleeve B guide

Throttle side......Fit the holder cap

to the end of the cable and fix it by the nut.

Shift side......Fit the sleeve B guide

to the end of the cable and fix it by the nut.

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Installation of the Remote Control

Cable (engine side) and the Cord Assembly (Wiring Harness) :

3

Ball joint

Cable of the shift side

Shift lever

Lower cowl

Lock pin

Steering hook plate

Neck of remote control cable

Washer

Advancer arm

Holder cap: Connect remote control cable to ball joint

Cable of the throttle side

Grommet is installed on the Lower motor cover

Cable outer groove

Cable clip

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INSTALLATION

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2

Fitting of Remote Control Cable to Engine

Throttle side......Set the throttle cable to the cable clip and then connect the holder

cap to the ball joint of advancer arm.

Shift side......Set the shift cable to the cable clip and then insert the lock pin at the

shift lever ﬁtting hole and turn it 90° to lock it.

Put the control lever in the Neutral position and the free accel lever in the fully closed position.

Be careful not to loop the remote control cables to a diameter of 406 mm (16 inches) or less.

Note

Conﬁrm whether the engine side shift is in gear when shifting the control lever of the remote control to its ﬁrst position in Forward or Reverse (about 32°) and whether the throttle of the carburetor is fully open when shifting the lever further. Conﬁrm whether the carburetor’s throttle is fully closed when the control lever is shifted to the Neutral position. If it is not, adjust the position of the ball holder.

TOHATSU M 25H, M 30H, M 40C Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

YOUR TOHATSU OUTBOARD MOTOR

CONTENTS

GENERAL SAFETY INFORMATION

SPECIFICATIONS

NAMES OF PARTS

INSTALLATION

Mounting the outboard motor on boat

Installing the remote control devices