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TOHATSU M 2.5A2 Owner's Manual

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OWNER'S
MANUAL
M 2.5A2
3.5A2
3.5B
OB No.003-11045-6

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  • Page 1 OWNER’S MANUAL M 2.5A2 3.5A2 3.5B OB No.003-11045-6...
  • Page 2 INJURY OR DEATH. KEEP THIS MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE. Copyright © 2011 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...
  • Page 3 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.
  • Page 4 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.

  • Page 5: Table Of Contents

    CONTENTS GENERAL SAFETY INFORMATION ........8 SPECIFICATIONS .
  • Page 7 INDEX GENERAL SAFETY INFORMATION 1. SPECIFICATIONS 2. NAMES OF PARTS 3. INSTALLATION 4.PRE-OPERATING PREPARATIONS 5.ENGINE OPERATION 6.REMOVING AND CARRYING THE OUTBOARD MOTOR 7.TRAILERING 8.ADJUSTMENT 9.INSPECTION AND MAINTENANCE 10.TROUBLESHOOTING 11.TOOL KIT AND SPARE PARTS 12.OPTIONAL ACCESSORIES 13.PROPELLER TABLE...

  • Page 8: General Safety Information

    GENERAL SAFETY INFORMATION 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,"...
  • Page 9 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.

  • Page 10: Specifications

    SPECIFICATIONS 2.5A2, 3.5A2, 3.5B2 MODEL 2.5A2 3.5A2 3.5B2 Item Overall Length mm (in) 550 (21.7) 195 (7.7) 220 (8.7) Overall Width mm (in) Overall Height S·L mm (in) 955 (37.6) · 1,082 (42.6) Transom Height S·L mm (in) 435 (17.1) · 562 (22.1) 12.5 (28) 13 0 (29) S kg (lb)

  • Page 11: Names Of Parts

    NAMES OF PARTS 2.5A2, 3.5A2, 3.5B2 Air Vent Screw Clamp Screw Fuel Tank Cap Thrust Rod Top Cowl Oil Plug (Upper) Plug Cap Cover Anti Ventilation Plate Fuel Cock Water Inlet (3.5B2 only) Clamp Bracket Gear Case Drive Shaft Housing Oil Plug (Lower) Propeller Throttle Lever...

  • Page 12: Installation

    INSTALLATION 1. Mounting the outboard motor on boat ������� Bottom of hull 30-50 mm Most boats are rated and certified in (1.2-2 in) terms of their maximum allowable Anti Ventilation Plate horsepower, as shown on the boat’s certification plate. Do not equip your boat with an outboard motor that exceeds this limit.
  • Page 13 INSTALLATION ������� ������� • Before beginning the running test, • Mounting the outboard motor without check that the boat with maximum following this manual can lead to capacity loading floats on the water unsafe conditions such as poor in a proper attitude. Check the maneuverability, lack of control or fire.

  • Page 14: Pre-Operating Preparations

    PRE-OPERATING PREPARATIONS ������ 1. Recommended gasoline types Consult an authorized dealer for details ������� on handling of gasoline, if necessary. Gasoline and its vapors are very Use of low-quality gasoline results in flammable and can be explosive. a short engine life as well as starting difficulties and other engine problems.
  • Page 15 TOHATSU recommend the use of gasoline if its ethanol content is less ������� than 10% or methanol content is less than 5%, only in case alcohol free Do not fill the fuel tank over capacity.

  • Page 16: Recommended Engine Oil

    PRE-OPERATING PREPARATIONS 2. Recommended engine oil Note Use a genuine engine oil or recommended Use of engine oils that do not meet one. Refer to your Distributor. these requirements will result in reduced engine life, and other engine problems. Will not recommend use of other two stroke engine oil.
  • Page 17 PRE-OPERATING PREPARATIONS Engine oil – gasoline mixing procedure For quantities of engine oil and gasoline to be pre-mixed, refer to table in previous page. ������� ● Do not use other than two stroke engine oil with specified grade, or the engine may be damaged. ●...

  • Page 18: Break-In

    PRE-OPERATING PREPARATIONS 3. Break-in Note Proper break-in allows outboard Your new outboard motor and lower motor to deliver it full performance for unit require break-in for the moving longer service life. c o m p o n e n t s a c c o r d i n g t o t h e conditions described in the following �������...

  • Page 19: Engine Operation

    ENGINE OPERATION 2 Loosen the air vent screw on the 1. Starting tank cap. Note The engine will not start unless the switch lock has been properly connected into the emergency stop switch. ������� Do not operate the engine with gear 3 Make sure that the shift lever is in the case out of water.
  • Page 20 ENGINE OPERATION 4 Turn the fuel cock-lever to the 6 Set the throttle lever to the “START” “OPEN” position. position. Note If fuel is not supplied immediately to START the carburetor (new engine or after cleaning), wait for about 15 seconds for the proper quantity of fuel to flow into the carburetor after opening the fuel cock.
  • Page 21 ENGINE OPERATION 8 W h e n t h e e n g i n e h a s s t a r t e d , immediately return the choke lever to the “OPEN” position then move the throttle lever downward to slow speed. Close Open �������...

  • Page 22: Warming Up The Engine

    ENGINE OPERATION ������� 2. Warming up the engine • When the engine cover and recoil War m the engine at low engine starter have been removed for speeds for about three minutes. This emergency starting, take extreme allows the lubricating oil to circulate to care that the operator’s clothes or other items do not get caught the all parts of the engine.

  • Page 23: Forward And Reverse

    ENGINE OPERATION Engine speed 3. Forward and reverse Idling speed after warming up. Remark: In case of cold engine ������� starting, idling speed is increased about 300 rpm for several minutes. Before shifting into forward or reverse, make sure that boat is properly moored Clutch in Clutch off and outboard motor can be steered...
  • Page 24 ENGINE OPERATION Reversing Note Return the throttle lever to the “SLOW” position and when the engine speed When moving astern, be sure to operate the motor at a low speed has reached the lowest rpm, move without unnecessary increase of the the shift lever to the “NEUTRAL”...

  • Page 25: Speed Control

    ENGINE OPERATION Speed Control ������� The speed is controlled by operating Do not tilt up or down outboard motor the throttle lever. Moving the throttle when swimmer(s) or passenger is near to lever upward increases the speed, prevent them from being caught between and moving it downward decreases outboard motor body and clamp bracket the speed.

  • Page 26: Stopping

    ENGINE OPERATION ������� 4. Stopping • This stop switch is provided for the 1 Reduce the engine speed to idling safety of the driver. If the lock is rpm, and release the lock of the released from the stop switch, the stop switch or push the stop switch engine will stop.

  • Page 27: Trim Angle

    ENGINE OPERATION 5. Trim angle The trim angle of the outboard motor can be adjusted to suit the transom angle of the hull, and load conditions. Choose an appropriate trim angle that will allow the anti ventilation plate to run parallel to the water surface during operation.

  • Page 28: Tilt Up And Tilt Down

    ENGINE OPERATION Tilt down 6. Tilt up and tilt down Pull the outboard motor fully toward you and release the tilt stopper knob ������� from the tilt-up position. When tilting up or down, be careful not ������� to place your hand between the swivel bracket and the clamp bracket.

  • Page 29: Outboard Motor Position In Tilt Up

    ENGINE OPERATION 7. Outboard motor position in tilt up 8. Mooring the Boat When the outboard motor is in the ������� tiltup position, the tilt handle side must be in the upward direction. When tilting up or down, be careful not to place your hand between the swivel bracket and the clamp bracket.

  • Page 30: Removing And Carrying The Outboard Motor

    REMOVING AND CARRYING THE OUTBOARD MOTOR 1. Removing the outboard motor 2. Carrying the outboard motor 1 Stop the engine. Keep the outboard motor in a vertical 2 Close the fuel cock and air vent position when carrying. screw. 3 Remove the outboard motor from boat and completely drain the water from the gear case.

  • Page 31: Storing The Outboard Motor

    REMOVING AND CARRYING THE MOTOR 3. Storing the outboard motor Outboard motor should be stored in a vertical position. Note If the outboard motor must be laid down be sure the tiller handle faces down as shown in the drawing below. Elevate power unit 2 inches to 4 inches if traveling to avoid oil spillage.

  • Page 32: Trailering

    TRAILERING ������� Do not go under outboard motor tilted up even if it is supported by support bar, or accidental fall of outboard motor could lead to severe personal injury. ������� Close air vent screw of fuel tank and fuel cock before carrying or storing outboard motor and fuel tank, or fuel A: G ro u n d c l e a r a n c e s h o u l d b e may leak, potentially catching fire.

  • Page 33: Adjustment

    ADJUSTMENT 1. Steering friction Note The steering adjust screw is used to The steering friction can be adjusted adjust the friction load of the steering, in accordance with your preference but not to fix the steering. Excess by turning the adjusting screw. tightening of the adjustment screw may cause damage to the swivel bracket.

  • Page 34: Inspection And Maintenance

    INSPECTION AND MAINTENANCE Care of your outboard motor ������� To keep your outboard motor in the • Your personal safety and that of your best operating condition, it is very passengers depends on how well you important that you perform daily and maintain your outboard motor.

  • Page 35: Daily Inspection

    INSPECTION AND MAINTENANCE 1. Daily inspection Perform the following checks before ������� and after use. Do not use outboard motor if any abnormality is found during pre- operation check or it could result in severe damage to the motor or severe personal injury.
  • Page 36 INSPECTION AND MAINTENANCE Washing outboard motor ������� When the engine has been used in Never start or operate the engine salt water or polluted water, wash the indoors or in any space which is not exterior and flush the cooling water well ventilated.
  • Page 37 INSPECTION AND MAINTENANCE ■ Use flushing plug. 1 Remove propeller (refer to Propeller Replacement). Remove the water plug from the outboard motor, and screw in the flushing plug. 2 Attach a water hose to the flushing plug. Turn on the water and adjust the flow.
  • Page 38 INSPECTION AND MAINTENANCE Replacing the propeller and shear pin ������� A worn-out or bent propeller will lower Do not hold propeller with hand(s) the motor's performance, and cause when loosening or tightening propeller engine trouble. nut. Put a piece of wood block Before removing the propeller, remove between propeller blade and anti the spark plug caps from the spark...
  • Page 39 INSPECTION AND MAINTENANCE Replacing the spark plugs 5 Attach spark plug and tighten to specified torque. ������� Use spark plugs (NGK BP6HS-10 or • Do not reuse spark plug with damaged BP6RHS-10) or recommended ones. insulation, or sparks can leak through crack, potentially leading to electric shock, explosion and/or fire.
  • Page 40 INSPECTION AND MAINTENANCE Replacing the anode A sacrificial anode protects the o u t b o a r d m o t o r f r o m g a l v a n i c corrosion. Anode is located on the gear case, clamp bracket and the cylinder.

  • Page 41: Periodic Inspection

    INSPECTION AND MAINTENANCE 2. Periodic inspection It is important to inspect and maintain your outboard motor regularly. At each interval on the chart below, be sure to perform the indicated servicing. Maintenance intervals should be determined according to the number of hours or number of months, whichever comes first.
  • Page 42 INSPECTION AND MAINTENANCE Replacing gear oil ������� ������� Do not reuse oil plug gasket. Always use new gasket and tighten oil plug • Be sure that outboard motor is properly to prevent entry of water into secured to transom or service lower unit.

  • Page 43: Off-Season Storage

    INSPECTION AND MAINTENANCE 7 Apply grease to all sliding parts, 3. Off-season storage bolts and nuts. 8 Wipe off any water and salt on the Before you put your outboard motor electrical components using a dry in storage, it is a good opportunity to cloth.

  • Page 44: Motor Submerged In Water

    INSPECTION AND MAINTENANCE 5. Motor submerged in water 6. Cold weather precautions After taking your outboard motor out If you moor your boat in cold weather of the water, immediately take it to at temperatures below 0˚C (32˚F), your dealer. there is the danger of water freezing The following are the emergency in the cooling water pump, which may...

  • Page 45: Troubleshooting

    TROUBLESHOOTING If you encounter a problem, consult the check list below to determine the cause and to take the proper action. An authorized dealer will always be happy to provide any assistance and information. Possible cause Empty fuel tank ● ●...
  • Page 46 TROUBLESHOOTING Possible cause Spark plugs other than specified ● ● ● ● ● Dirt, soot, etc. on spark plugs ● ● ● ● ● No spark or weak spark ● ● ● ● ● Short circuit of engine stop switch ●...

  • Page 47: Tool Kit And Spare Parts

    TOOL KIT AND SPARE PARTS The following a list of the tools and spare parts provided with the motor. Items Quantity Remark Tool Bag Pliers Socket Wrench 21mm Service Tools Socket Wrench Handle Phillips Screwdriver No. 2 Spark Plug NGK BPR6HS-10 Shear pin Spare Parts* Spl t Pin...

  • Page 48: Optional Accessories

    OPTIONAL ACCESSORIES Touch-up Paint Propeller Genuine gear oil (500mL) Genuine Engine Oil (0.4L, 1L, 4L, 20L) Flushing plug...

  • Page 49: Propeller Table

    PROPELLER TABLE PROPELLER TABLE Use a genuine propeller. A propeller must be selected so that the engine rpm measured at wide open throttle while cruising is within the recommended range. Model 2.5A2 3 5A2 3.5B2 Propeller 4.5 (Plastic) – – Propeller 6 (Plastic) Propeller 6 (Aluminum) Propeller 7 (Plastic)
  • Page 50 M E M O...
  • Page 52 OWNER’S MANUAL 2.5A2 3.5A2 TOHATSU CORPORATION 3.5B Address : 5-4, 3-chome, Azusawa, Itabashi-ku, TOKYO, 174-0051 JAPAN Phone : TOKYO (03)3966-3117 FAX : TOKYO (03)3966-2951 Website : www.tohatsu.co.jp 003-11045-6 1101NB Printed in Japan...

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M 3.5a2M 3.5b

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