TOHATSU M 25H Owner's Manual
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TOHATSU M 25H Owner's Manual

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  • Page 3 OWNER’S MANUAL M 25H M 30H OB No.003-11055-7AF1...
  • Page 4 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.
  • Page 5 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.

  • Page 6: Serial Number

    ENOM00005-A 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 when order- ing parts, and when making technical or warranty inquiries. Serial Number: ENOF01800-0 ENOF01801-0...
  • Page 7 ENOM00007-0 NOTICE: DANGER/WARNING/CAUTION/Note Before installing, operating or otherwise handling your outboard motor, be sure to thor- oughly read and understand this Owner's Manual and carefully follow all of the instruc- tions. Of particular importance is information preceded by the words “DANGER,” “WARNING,”...

  • Page 9: Table Of Contents

    CONTENTS 1. GENERAL SAFETY INFORMATION ....... 10 2. SPECIFICATIONS ..........12 3.
  • Page 10 11. TROUBLESHOOTING ......... . 68 12.
  • Page 11 INDEX 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 10. INSPECTION AND MAINTENANCE 11. TROUBLESHOOTING 12. TOOL KIT AND SPARE PARTS 13.

  • Page 12: General Safety Information

    GENERAL SAFETY INFORMATION ENOM00009-0 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 13 GENERAL SAFETY INFORMATION 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 52).

  • Page 14: Specifications

    SPECIFICATIONS ENOM00810-B MODEL FEATURE Model M25H M30H Type Transom heights Tiller Handle Remote Control Mnual tilt *1: Option ENOM00811-C MODEL NAME EXAMPLE M30HMFL Horse Product Starter Steering Model description Shaft length power generation system system P=Remote control S= Short 15 in M (X)=Two stroke E= Electrical (Pleasure)
  • Page 15 Genuine Gear Oil or API GL5,SAE #80 - #90, Approx. 360 (12.2) Gear Reduction Ratio 1.92 (12 : 23) Remark: Specifications subject to change without notice. *1 With manual. Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).

  • Page 16: Parts Name

    PARTS NAME ENOM00820-0 ENOF01802-0 Tilt Handle Drive Shaft Housing Fuel Filter Top Cowl Thrust Rod Cooling Water Check Port Clamp Bracket Water Plug Clamp Screw Reverse Lock Lever Throttle Grip Anti-Ventilation Plate Adjust Nut Trim Tab Shift Lever Sub-Water Inlet Starter Handle Water Inlet Stop Switch...
  • Page 17 PARTS NAME ENOM01102-0 ENOF01802-A Tilt Handle Drive Shaft Housing Maine Switch Top Cowl Thrust Rod Spark Plug Cooling Water Check Port Clamp Bracket Fuel Filter Water Plug Clamp Screw Reverse Lock Lever Throttle Grip Anti-Ventilation Plate Adjust Nut Trim Tab Shift Lever Sub-Water Inlet Starter Handle...
  • Page 18 PARTS NAME ENOM01103-0 ENOF01802-B Tilt Handle Drive Shaft Housing Top Cowl Thrust Rod Cooling Water Check Port Clamp Bracket Water Plug Clamp Screw Reverse Lock Lever Shift Lever Anti-Ventilation Plate Starter Handle Trim Tab Battery Cable Sub-Water Inlet Fuel Connector Water Inlet Spark Plug Propeller...
  • Page 19 PARTS NAME ENOM00822-0 Remote control box & Fuel tank ENOF00127-F Control Lever Fuel connector (Fuel tank side) Neutral lock arm Free throttle lever Main switch Stop switch Stop switch lock Stop switch lanyard Fuel gauge Air vent screw Fuel tank cap Fuel connector (Engine side) Primer bulb...

  • Page 20: Label Locations

    LABEL LOCATIONS ENOM00019-A Warning label locations ENOF01803-0...
  • Page 21 LABEL LOCATIONS Warning label urge to read the owner’s Warning regarding gasoline. manual . ENOF00005-E Warning regarding gasoline (See page 26). ENOF00005-W Warning regarding rotating object. ENOF00005-L Warning regarding gasoline (See page 26). ENOF00005-X Warning regarding high voltage. 3C8-72181-0B ENOF00005-M For RC model Warning regarding...
  • Page 22 LABEL LOCATIONS ENOM01001-0 Serial number label locations r o t l a i ENOF01804-0 1. Model code(Model name) 2. Rated power 3. Dry mass weight 4. Serial No. 5. Manufacture name 6. Manufacture address...

  • Page 23: Installation

    INSTALLATION ENOM00024-B Keep the outboard motor in a vertical posi- 1. Mounting the outboard motor on tion when mounting. 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.
  • Page 24 INSTALLATION ENOM01201-0 ing, in high waves, water may enter the engine cylinders. Twin-engine Installation Incorrect outboard motor mounting When installing two outboard engines, be height or existence of underwater sure to keep an interval of approximately object(s), such as hull bottom design, 580 mm (22.8 in) between the two.

  • Page 25: Remote Control Device Installation

    INSTALLATION ENOW00008-A Make sure there are no obstacles that can interfere with the operation of the remote CAUTION control cable. Mounting bolts should be installed with the bolt head at inside surface of the ENOW00850-0 transom. Mounting bolts installed with Remote control cable length the threaded end at the inside surface of ENOW00100-A...

  • Page 26: Battery Installation

    INSTALLATION ENOM00029-A ENOW00014-0 3. Battery installation CAUTION Make sure that the battery leads do not ENOW00012-0 get stuck between the outboard motor WARNING and boat when turning, etc. The starter motor may fail to operate if Battery electrolyte contains sulfuric acid the leads are incorrectly connected.
  • Page 27 INSTALLATION 2. Connect the positive lead (+) to the positive terminal (+) of the battery, and then connect the negative lead (—). W h e n d i s c o n n e c t i n g t h e b a t t e r y always remove the negative lead (—) first.

  • Page 28: Pre-Operating Preparations

    The fuel system components on your gasoline in the fuel tank for long periods TOHATSU engine will withstand up to 10% should be avoided. Long periods of stor- ethyl alcohol (hererinafter referred to as the age, common to boats, create unique prob- lems.

  • Page 29: Fuel Filling

    PRE-OPERATING PREPARATIONS age if alcohol has washed protective oil When or before refueling: films from internal components. Be sure to remove the static electricity charged in your body before refueling. The sparks due to static electricity may ENOW00018-0 cause explosion of flammable gasoline. WARNING Stop the engine, and do not start the engine during refueling.

  • Page 30: Engine Oil Recommendation

    PRE-OPERATING PREPARATIONS Will not recommend use of other two stroke engine oil. Add engine oil into fuel oil tank. The mixing ratio with gasoline is 50 : 1 (50 parts gaso- line and one part oil). Mix well by hand. The mixing ratio during break-in running is 25 : Mixing Ratio ENOF00027-A...
  • Page 31 PRE-OPERATING PREPARATIONS For quantities of engine oil and gasoline to Pour engine oil into fuel container, and then, gasoline. be pre-mixed, refer to table in previous page. Put cap on the container, and close tightly. When portable fuel tank is used for operation of outboard motor(s): Shake the container to mix engine oil and gasoline well and even.

  • Page 32: Break-In

    PRE-OPERATING PREPARATIONS ]ENOM00033-A 4. Break-In Your new outboard motor and lower unit ENOW00023-0 require break-in for the moving compo- CAUTION nents according conditions Operating the outboard motor without described in the following time table. break-in can shorten service life of the Please refer to ENGINE OPERATION sec- product.

  • Page 33: Engine Operation

    ENGINE OPERATION ENOM00042-0 tank is raised by heat from sources such as sun light. Before starting 1. Full open the air vent screw on the fuel ENOW00022-B tank cap. CAUTION Be sure to fill the engine before starting engine. (To properly fill the engine with oil follow the instructions.

  • Page 34: Starting The Engine

    ENGINE OPERATION ENOF00861-A ENOF00863-0 1. Pull 2. Insert 1. Test tank 2. Water 4. Squeeze primer bulb until it becomes 3. Over 10 cm (4 in.) stiff to feed fuel to carburetor. Direct arrow mark upward when priming. ENOW00036-0 CAUTION Be sure to stop engine immediately if cool- ing water check port is not discharging water, and check if cooling water intake is...
  • Page 35 ENGINE OPERATION ENOM01005-A 3. Set the throttle grip to START position. 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 Flo- tation Device.) ENOF01714-0 1.
  • Page 36 ENGINE OPERATION (For manual starter type) crank engine again after 10 seconds or more. 5. Pull the starter handle slowly until you feel engagement, keep pulling till you 5. Return the choke knob fully after feel less resistance. Then pull it quickly. engine has started.

  • Page 37: Emergency Starting

    ENGINE OPERATION 6. Stop pushing the key when the engine has started. The key returns to the original position, automatically. 7. Return the Free accel lever after engine has started. 8. Check the cooling water from cooling water check port. ENOF00870-0 1.
  • Page 38 ENGINE OPERATION Attach engine stop switch lanyard to 4. Insert the knotted end of the starter clothing or any part of body like arm rope into the notch in the flywheel and before starting engine. wind the rope around the flywheel sev- eral turns clockwise.

  • Page 39: Warming Up The Engine

    ENGINE OPERATION 8. Pull the starter handle slowly until you feel engagement, keep pulling till you ENOM00043-A feel less resistance. Then pull it quickly. 3. Warming up the engine ENOW00932-0 CAUTION Be sure to check that cooling water is coming out of the cooling water check port during warm up.

  • Page 40: Forward, Reverse, And Acceleration

    ENGINE OPERATION ENOM00046-A injury, and steering system and/or shift- ing mechanism may be damaged. 4. Forward, reverse, and acceleration ENOW00861-0 WARNING ENOW00037-0 WARNING Do not shift at high boat speed, or control may be lost, falling down or causing pas- Before shifting into forward or reverse, senger(s) to be thrown overboard.
  • Page 41 ENGINE OPERATION ENOM00890-A Acceleration Tiller handle type ENOW00867-0 ENOW00865-A WARNING CAUTION Sudden acceleration and deceleration may Do not force to shift when the throttle grip cause passenger(s) to be thrown over- is not in the fully closed position, other- board or falling down. wise, steering system and/or shifting Open throttle grip gradually.

  • Page 42: Stopping The Engine

    ENGINE OPERATION Acceleration ENOW00867-A CAUTION Sudden acceleration and deceleration may cause passenger(s) to be thrown over- board or falling down. Open throttle grip or control lever gradu- ally. ENOF00877-0 1. Forward (F) 2. Neutral (N) 3. Reverse (R) 4. Fully opened (Forward) 5.
  • Page 43 ENGINE OPERATION Tiller handle type Side mount RC type 1. Turn the throttle grip to the fully closed 1. Put the control lever in the Neutral position. position and run the engine for 2-3 minutes at idling speed for cooling down if it has been running at full speed.

  • Page 44: Steering

    ENGINE OPERATION Emergency engine stopping Remove stop switch lock to stop the engine. ENOF00892-0 Remote control type ENOF01824-B Right turn Turn the steering wheel to the right. Left turn Turn the steering wheel to the left. ENOF00884-0 1. Stop switch 2.
  • Page 45 ENGINE OPERATION Unsuitable trim position can cause loss ENOM00053-0 Improper trim angle (bow rises too of control of boat. When testing a trim high) position, run boat slow initially to see if it Set the thrust rod lower if the bow of the can be controlled safely.

  • Page 46: Tilt Up And Down

    ENGINE OPERATION Trim angle adjustment (Manual tilt ENOW00048-0 type) WARNING The transom angle adjustment 1. Stop the engine. When tilting up or down, be careful not to p l a c e y o u r h a n d b e t w e e n t h e s w i v e l 2.

  • Page 47: Shallow Water Operation

    ENGINE OPERATION 2. Tilt up position 3. Tilt down position ENOM00068-A 9. Shallow water operation ENOW00051-0 WARNING During shallow water operation, be careful not to place your hand between the swivel ENOF01813-0 bracket and the clamp bracket. Be sure to 1.
  • Page 48 ENGINE OPERATION Manual tilt type 1. Shallow water running position: Put the reverse lock lever in the tilt up position, and tilt up the outboard motor to put the outboard motor in the shal- low water running position. ENOF01813-0 1. Reverse lock lever 2.

  • Page 49: Removing And Carrying The Outboard Motor

    REMOVING AND CARRYING THE OUTBOARD MOTOR ENOM00070-B ENOW00065-0 1. Removing the outboard motor WARNING Close air vent screw of fuel tank before ENOW00064-0 carrying or storing outboard motor and fuel CAUTION tank, or fuel may leak, potentially catching fire. Engine may be hot immediately after oper- ating and could cause burns if touched.

  • Page 50: Traillering

    REMOVING AND CARRYING THE OUTBOARD MOTOR ENOW00073-A WARNING 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. ENOF00075-1 ENOF01827-0 ENOW00068-0 WARNING ENON00021-B Note Close air vent screw of fuel tank and fuel If the outboard motor must be laid down cock before carrying or storing outboard be sure drain the fuel, then the port side...
  • Page 51 REMOVING AND CARRYING THE OUTBOARD MOTOR ENOF00073-A 1. Ground clearance should be provided sufficiently. 2. Transom saver bar ENOW00067-0 WARNING 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.

  • Page 52: Adjustment

    ADJUSTMENT ENOM00073-B be made with the throttle adjustment 1. Steering friction screw. ENOW00074-A WARNING Do not overtighten the steering friction lever it could result in difficulty of move- ment resulting in the loss of control caus- ing an accident and could lead to severe injury.
  • Page 53 ADJUSTMENT achieved, adjust the trim tab located under the anti-ventilation plate. If the boat veers toward the left direct the trim tab towards A (left from rear of boat). If the boat veers toward the right direct the trim tab towards B (right from rear of boat).

  • Page 54: Inspection And Maintenance

    INSPECTION AND MAINTENANCE ENOM00077-0 Care of your outboard motor To keep your outboard motor in the best operating condition, it is very important that you perform daily and periodic main- tenance as suggested in the maintenance schedules that follow. ENOW00077-0 CAUTION Your personal safety and that of your passengers depends on how well you...

  • Page 55: Daily Inspection

    INSPECTION AND MAINTENANCE ENOM01203-0 1. Daily Inspection Perform the following checks before and ENOW00078-0 after use. WARNING Do not use outboard motor if any abnor- mality is found during pre-operation check or it could result in severe damage to the motor or severe personal injury.
  • Page 56 INSPECTION AND MAINTENANCE ENOM00083-0 ment as this can cause damage to the out- Washing outboard motor board motor. ENOW00081-0 ENOW00922-0 WARNING CAUTION Do not start engine without removing pro- To prevent the engine from starting when peller, or accidentally turning propeller you are near the propeller, remove the stop could cause personal injury.
  • Page 57 When the engine is started in the test tank, If the fuse continues to blow, request an to avoid over heating and water pump authorized Tohatsu dealer to inspect the damage, be sure the water level is at least outboard motor.

  • Page 58: Periodic Inspection

    INSPECTION AND MAINTENANCE ENOM01204-0 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 59 INSPECTION AND MAINTENANCE ENOM00093-A ENOM00094-0 Fuel filters and fuel tank cleaning Fuel filter (for engine) 1. Check in the cup for water and debris. ENOW00093-B WARNING Gasoline and its vapors are very flammable and can be explosive. Keep out of reach of children. Avoid repeated or prolonged contact with skin or breathing of vapor.
  • Page 60 INSPECTION AND MAINTENANCE ENOM00096-C board motor could lead to severe per- Fuel filter (for fuel tank) sonal injury. 1. Remove the fuel pickup elbow of the fuel tank by turning it counterclockwise ENON00934-0 Note 2. Clean the fuel filter and check the O- Please dispose of used oil in a manner that ring.

  • Page 61: Propeller Replacement

    INSPECTION AND MAINTENANCE ENON00032-0 Note If water in the oil, giving it a milky colored appearance. Contact your dealer. ENON00033-0 Note Use genuine gear oil or the recommended one (API GL-5: SAE #80 to #90). Required volume: approx. 360 mL (12.2 fl.Oz).
  • Page 62 INSPECTION AND MAINTENANCE ENOF00084-D ENOM00087-B Spark plugs replacement ENOF00084-B ENOW00087-0 WARNING 2. Remove the split pin, propeller nut and washer. Do not reuse spark plug with damaged 3. Remove the propeller and thrust insulation, or sparks can leak through holder. crack, potentially leading to electric shock, explosion and/or fire.
  • Page 63 INSPECTION AND MAINTENANCE 5. Inspect the spark plug. Replace the the correct torque as soon as possible with a torque-wrench. spark plug if the electrodes are worn or i f t h e i n s u l a t o r s a re c r a c k e d o r chipped.

  • Page 64: Anode Replacement

    INSPECTION AND MAINTENANCE ENOM00088-A Anode replacement A sacrificial anode protects the outboard motor from electrolytic corrosion. Anode is located on the gear case, cylinder etc.. When the anode is eroded more than 1/3 of origi- nal size, replace it. ENON00029-0 Notes Never grease or paint the anode.
  • Page 65 INSPECTION AND MAINTENANCE ENOM00960-0 Grease point Apply water proof grease to the parts shown below. ENOF01821-0 *1 : Other side (Opposite side) *2 : Both side...

  • Page 66: Off-Season Storage

    INSPECTION AND MAINTENANCE ENOM00100-A 2. Remove the fuel hose from the out- 3. Off-season storage board motor. 3. Drain all fuel from the fuel hoses, fuel ENOW00934-0 pump, fuel filter (See page 57) and car- WARNING buretor (See page 66), and clean these parts.

  • Page 67: Adding A Fuel Stabilizer

    INSPECTION AND MAINTENANCE 8. Stand the outboard motor up vertically in a dry place. ENOF01815-0 1. Handle ENOM00950-A Adding a fuel stabilizer When adding a fuel stabilizer additive (commercially available), first fill the fuel tank with fresh oil and fuel. If the fuel tank is only partially filled, air in the tank can cause the fuel to deteriorate during stor- age.

  • Page 68: Pre-Season Check

    INSPECTION AND MAINTENANCE ENOM00970-B Fuel system draining ENOW00028-A WARNING For details on handling fuel, contact an authorized dealer. Fuel and fuel vapors are extremely flamma- ble and can be explosive. If fuel is spilled, wipe it up immediately. Keep the fuel tank well away from sources of ignition, e.g.

  • Page 69: Submerged Outboard Motor

    INSPECTION AND MAINTENANCE 8. Run the engine for 5 minutes at the slow- ENOM00107-A est speed. 7. Striking underwater object 9. Run the engine for 10 minutes at half throttle. The oil used for storage inside ENOW00935-0 the engine will be circulated out to assure CAUTION optimum performance.

  • Page 70: Troubleshooting

    TROUBLESHOOTING ENOM01106-0 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 Incorrect connection of fuel system Air entering fuel line Deformed or damaged fuel pipe...
  • Page 71 TROUBLESHOOTING Possible cause Incorrect adjustment of throttle link Insufficient cooling water flow, clogged or defective pump Faulty thermostat Cavitation or ventilation Incorrect propeller selection Damaged and bent propeller Improper thrust rod position Unbalanced load on boat Transom too high or too low...

  • Page 72: Tool Kit And Spare Parts

    TOOL KIT AND SPARE PARTS ENOM01206-A The following a list of the tools and spare parts provided with the motor. Name Quantity Remark Tool Bag Pliers Socket Wrench 10 x 13 mm Servicing Tools Socket Wrench 21 mm Socket Wrench Handle Screwdriver (Phillips-type and flat head) Adapter-type Rope...

  • Page 73: Propeller Table

    PROPELLER TABLE ENOM01207-0 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. 25H: 5000 to 6000 rpm 30H: 5150 to 5850 rpm Propeller Size (Diameter x pitch) Mark inch...
  • Page 74 OWNER’S MANUAL M 25H M 30H 003-11055-7AF1 1512NB Printed in Japan...

This manual is also suitable for:

M 30h

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