TOHATSU MFS 25D Owner's Manual
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TOHATSU MFS 25D Owner's Manual

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O W N E R' S
M A N U A L
AAAA
MFS 25D
MFS 30D
OB No.003-11172-0BB1

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Summary of Contents for TOHATSU MFS 25D

  • Page 1 O W N E R’ S M A N U A L AAAA MFS 25D MFS 30D OB No.003-11172-0BB1...
  • Page 2 MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE. Copyright © 2022 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 3 In case you encounter any problems, please contact an authorized TOHATSU service shop or dealer for assistance. Tohatsu Corporation reserves the right to change, modify, add, or remove a part or whole of the owner’s manual without prior notice and incurring any obligations.
  • Page 4 ENOM00003-1 PRE-DELIVERY INSPECTION Make sure Pre-delivery inspection has been properly done by authorized TOHATSU dealer before operating your outboard motor. ENOM00005-1 Serial Number Your outboard motor has a unique serial number. The serial number is identification of outboard motor and is located on the outboard motor as shown in the figures below.
  • Page 5 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 7: Table Of Contents

    2. Battery installation..........28 3. TOCS (Tohatsu Onboard Communication System) installation..29 6.
  • Page 8 8. Operation with multiple outboard motors ......90 11. TROUBLESHOOTING ..........91 12.
  • Page 9 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 10: General Safety Information

    GENERAL SAFETY INFORMATION ENOM00009-1 SAFE OPERATION OF BOAT As the operator/driver of a 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 11 Be sure to use genuine parts, genuine lubricants, or recom- mended lubricants. Be aware that the installation and use of parts not approved by Tohatsu Corporation will void warranty and may lead to unsafe operating conditions. ENOM00011-1...

  • Page 12: Specifications

    SPECIFICATIONS ENOM00810-B MODEL FEATURE Model MFS25D MFS30D Type Transom heights Basic Tiller Handle Multi-function tiller handle — — — — Remote Control — — — — Power Tilt — — — — Gas-assisted tilt — — — — — — Manual tilt —...
  • Page 13 26 : 12 (2.17) Operator Sound Pressure 83.2 (ICOMIA 39/94 Rev.1) dB (A) Hand Vibration Level (ICOMIA 38/94 Rev.1) m/s Remark: Specifications are subject to change without notice. *1 With propeller Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
  • Page 14 SPECIFICATIONS Service data MFS 25/30D Item Model ET (EFT) with basic tiller handle Grade Unleaded Regular Gasoline : R+M/2: 87 or higher RON: 91 or higher Fuel L (US gal) 25 (6.60) Garde API: SH, SJ, SL, SAE: 10W-30, 10W-40 Engine Oil 1500 (1.6/1.3) without oil filter replacement (US/Imp.qt)
  • Page 15 26 : 12 (2.17) Operator Sound Pressure 83.2 (ICOMIA 39/94 Rev.1) dB (A) Hand Vibration Level (ICOMIA 38/94 Rev.1) m/s Remark: Specifications are subject to change without notice. *1 With propeller Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
  • Page 16 SPECIFICATIONS Service data MFS 25/30D Item Model ET (EHT) ET (EPT) with RC with multifunction tiller handle Grade Unleaded Regular Gasoline : R+M/2: 87 or higher RON: 91 or higher Fuel L (US gal) 25 (6.60) Garde API: SH, SJ, SL, SAE: 10W-30, 10W-40 Engine Oil 1500 (1.6/1.3) without oil filter replacement (US/Imp.qt)

  • Page 17: Parts Name

    PARTS NAME ENOM00820-0 ENOF02503-0 Tilt Handle Splash Plate Flushing Connector Cap Top Cowl Anode Warning Lamp Bottom Cowl Clamp Bracket Stop Switch Cooling Water Check Port Clamp Screw Stop Switch Lanyard Oil Drain Plug Basic Tiller Handle Push Switch Anti-ventilation Plate Throttle Grip Trim Tab Shift Lever...
  • Page 18 PARTS NAME ENOM00020-0 ENOF02504-0 Tilt Handle Splash Plate Spark Plug Top Cowl Anode Oil Filler Cap Bottom Cowl Clamp Bracket Flushing Connector Cap Cooling Water Check Port Clamp Screw Warning Lamp Oil Drain Plug Stop Switch Basic Tiller handle Anti-ventilation Plate PT Switch *1 Stop Switch Lanyard Trim Tab...
  • Page 19 PARTS NAME ENOM00020-0 ENOF02505-0 Tilt Handle Oil Plug (Upper) Spark Plug Top Cowl Splash Plate Oil Filler Cap Bottom Cowl Anode Flushing Connector Cap Cooling Water Check Port Clamp Bracket Warning Lamp PT Switch Stop Switch Multi-function Tiller handle *1 Oil Drain Plug PT Switch Stop Switch Lanyard...
  • Page 20 PARTS NAME ENOM00822-0 Remote control box & Fuel tank ENOF02539-A Control Lever Fuel Gauge Neutral lock arm Air Vent Screw PT switch Fuel Tank Cap Free throttle lever Tab Lock Main switch Primer Bulb Stop switch Fuel Connector (Fuel tank Stop switch lock side) Stop switch lanyard...

  • Page 21: Label Locations

    LABEL LOCATIONS ENOM00019-A Warning label locations ENOF02506-A...
  • Page 22 LABEL LOCATIONS 1, 2-4. Read owner's manual. Engine stop switch (See page 41,50 and 52). 3WL-72180-0 ENOF00131-B 2-1. Hot surface. When laying down the out board 2-2. Hazard caused by rotating parts. motor, be sure this decal is facing up. 2-3.
  • Page 23 LABEL LOCATIONS Warning regarding gasoline (See page Warning tag regarding combination of 30). fuel tank and primer bulb ass'y (See page 38). ENOF00005-L Warning regarding gasoline (See page 30). ENOF00005-M Warning regarding gasoline (See page ENOF00005-T 30). Warning tag regarding instructions of the fuel tank cap (See page 38).
  • Page 24 ENOF02507-A ADJUSTMENTS. EPA Emissions Regulations The Emission Control Information label Outboards sold by Tohatsu America Cor- was affixed to engines as permanent evi- poration in the United States are certi- dence of EPA certification. fied to the United States Environmental...

  • Page 25: Installation

    INSTALLATION ENOM00024-A ENOW00009-2A 1. Mounting the outboard WARNING motor on boat Mounting the outboard motor without following this manual can lead to unsafe ENOW00006-1B conditions such as poor maneuverability, WARNING lack of control or fire. Loose clamp screws and/or mounting To avoid personal injury or damage of equip- hardware can lead to the release or dis- ment , make sure the allowable lifting capac-...
  • Page 26 INSTALLATION ENOM00026-A ENOM00832-A Transom matching Mounting the outboard motor Be sure that the anti ventilation plate of Manual tilt type the outboard motor is 0–25 mm (0–1 in) 1. Set the outboard motor to appropri- below the bottom of hull. ate position.
  • Page 27 INSTALLATION ENOW00945-0 CAUTION (12.9”) Please inspect whether there is a loosen- ing of the clamp screw or mounting bolts before departure. Loosening may cause a dangerous situa- ø12.5 tion, such as loss of control. PT type 1. Set the outboard motor to appropri- ate position.

  • Page 28: Battery Installation

    INSTALLATION ENOM00029-A ENOW00014-0 2. Battery installation CAUTION Make sure that the battery leads do not ENOW00012-1 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 29: Tocs (Tohatsu Onboard Communication System) Installation

    (—) an optional interface cable. Contact first. After connecting the positive authorized Tohatsu dealer for more terminal (+), securely place a cap on it details. to prevent short circuits. * Electric start model only ENOF00022-1 1.

  • Page 30: Pre-Operating Preparations

    When operating an outboard motor with The fuel system components on your gasoline containing ethanol, storing gasoline TOHATSU outboard motor will withstand in the fuel tank for long periods should be up to 10% ethyl alcohol (hereinafter avoided. Storing gasoline for long periods referred to as the "ethanol") content in...

  • Page 31: Fuel Filling

    PRE-OPERATING PREPARATIONS The static electricity may ignite the gaso- ENOW00018-1 line vapor during refueling. WARNING Stop the engine, and do not start the engine during refueling. Fuel leakage can cause fire or explosion, Do not smoke. potentially leading to severe injury or loss of Be careful not to overfill fuel tank.

  • Page 32: Engine Oil Filling

    PRE-OPERATING PREPARATIONS 1. Fully open the air vent screw on the ENOM00037-D 3. Engine oil filling fuel tank cap and release internal pressure. ENOW00022-2 CAUTION The engine oil is drained for shipping at the factory. Be sure to fill the engine oil to the proper level before starting the engine.
  • Page 33 PRE-OPERATING PREPARATIONS 10W−40 10W−30 ˚C ˚F ENOF00208-0 Engine oil volume (with out oil filter replacement) ENOF02510-0 Approximately 1500 mL (1.6/1.3 US/Imp. qt.) 1. Filler cap 2. Dipstick ENOW0002A-A 3. Filler port CAUTION Use of engine oils that do not meet these requirements will result in reduced engine life, and other engine problems.

  • Page 34: Break-In

    PRE-OPERATING PREPARATIONS ENOM00033-A 4. Break-In Your new outboard motor and lower unit ENOW00023-1 require break-in for the moving compo- CAUTION nents a ccording to the conditions Operating the outboard motor without described in the following time table. break-in can shorten life. Please refer to ENGINE OPERATION sec- If any abnormality is experienced during the tion (See page 38) to learn how to cor-...

  • Page 35: Warning System

    PRE-OPERATING PREPARATIONS ENOM00039-1 5. Warning system If outboard motor encounters an abnor- mal condition of fault, the warning buzzer will emit a continuous beep or intermit- tent short beeps. The warning lamp (LED) will synchronize with the buzzer and engine speed will be limited (engine will ENOF00851-A not stop).
  • Page 36 Therefore, the engine speed varies and is controlled following specified engine speed. MFS 30D: 6700 min (rpm) MFS 25D: 6200 min (rpm) Low speed ESG Low speed ESG is a device to prevent the engine from getting damage. If the engine has problems regarding cooling water, oil pressure, and sensors, the low speed ESG is activated not to ignite the spark plug, and disable fueling.
  • Page 37 (rpm), however you should not continue to run engine. High speed ESG ON: Engine speed will be limited to specified engine speed and engine will run rough until throttle is reduced. MFS 30D: 6700 min (rpm) MFS 25D: 6200 min (rpm)

  • Page 38: Engine Operation

    ENGINE OPERATION ENOM00042-0 ENOW00027-B Before starting CAUTION Before starting engine for the first time after ENOM00246-0 Oil Level checking reassembling engine or off-season storage, disconne c t stop switch lock and crank Check the engine oil level before each approximately 10 times in order to prime the use.
  • Page 39 ENGINE OPERATION a sealing mechanism as shown below: other- Connector type wise fuel spillage may occur when the con- 3-1.Connect the fuel connector to the nector is connected to the engine. engine and fuel tank. ENOF00036-0 Do not connect fuel connector except when operating engine.

  • Page 40: Starting The Engine

    ENGINE OPERATION 4. Squeeze primer bulb until it becomes 1. Water level is at least 10 cm (4 in.) above the anti-ventilation plate to avoid over- stiff to feed fuel to vapor separator. heating of the engine. Point the arrow mark upward when 2.
  • Page 41 ENGINE OPERATION This model is provided with start in gear 2. Set the shift lever in the Neutral posi- protection. tion. ENON00010-1 Note Start-in-gear protection prevents the engine from starting at other than neutral shift. In-gear starting of engine will move the boat immediately, potentially leading to fall down or causing passenger(s) to be thrown overboard.
  • Page 42 ENGINE OPERATION (For manual starter type) Multi-function tiller handle type This engine is equipped with a compres- 1. Be sure to install the stop switch lock sion release mechanism. to the stop switch, and attach the 4. Pull the starter handle slowly until you stop switch lanyard securely to the feel engagement, keep pulling till you operator or to the operator's PFD...
  • Page 43 ENGINE OPERATION 4. Set the throttle grip to START posi- tion. ENOF02512-A ENOF00866-2 1. Throttle grip 1. Warning lamp 5. Turn the main switch key to ON posi- ENOW00032-1 tion. CAUTION Do not hold turning starter motor more than 5 seconds, or the battery may be consumed, potenti ally making the engine star ting impossible and/or damaging the starter.
  • Page 44 ENGINE OPERATION Side mount RC type 4. Turn the main switch key to ON posi- tion. 1. Be sure to install the stop switch lock to the stop switch, and attach the 5. Turn the main switch key to START stop switch lanyard securely to the position and release the key when the operator or to the operator's PFD...
  • Page 45 ENGINE OPERATION and the top cowl after the engine has been started. Do not pull starter rope if any bystander is around. Attach engine stop switch lanyard to clothing or any part of body such as wrist, arm before starting engine the outboard motor.

  • Page 46: Warming Up The Engine

    ENGINE OPERATION 7. Set the control lever in the Neutral 4. Insert the knotted end of the starter position. rope into the notch in the flywheel 8. Pull the starter handle slowly until you and wind the rope clockwise around feel engagement, keep pulling till you the flywheel several turns.
  • Page 47 ENGINE OPERATION ENOM01826-0 ENOM00880-A Engine speeds Trolling speed control Idling speed after warming up. If the main switch key (for basic tiller han- Remark: The idling speed automatically dle model: Push switch) is pressed for 1 increases depending on the engine tem- (one) second during idling or trolling perature.

  • Page 48: Forward, Reverse, And Acceleration

    ENGINE OPERATION and trolling speed is set to 850 min personal injury, boat may swamp, and/or hull may be damaged. ( r p m ) w h e n t h e e n g in e sp e e d is Do not shift into Reverse during cruising, increased above 3,000 min (rpm) or...
  • Page 49 ENGINE OPERATION Forward ENOW00864-0 1. Turn the throttle grip to reduce CAUTION engine speed. 2. When the engine reaches trolling (or Do not increase engine speed unnecessarily when the shift is in neutral and reverse, or idling) speed, quickly shift the lever engine damage may occur.

  • Page 50: Stopping The Engine

    ENGINE OPERATION Acceleration ENOM0900-A Side mount RC type Open throttle grip or control lever gradu- ally. ENOF00879-2 ENOF00877-1 1. Forward (F) 1. Control lever 2. Neutral (N) ENOM01904-0 3. Reverse (R) 4. Fully opened (Forward) 5. Stopping the engine 5. Fully opened (Reverse) 6.
  • Page 51 ENGINE OPERATION 5. Turn the main switch key to the OFF position or push the stop switch. ( Do not forget to turn the key off). ENOF02516-0 1. Throttle grip 2. Put the shift lever in the Neutral posi- tion. Run the engine for 2-3 minutes at idling speed for cooling down if it has been running at full speed.
  • Page 52 ENGINE OPERATION ENOF00871-1 1. ON 2. START 3. OFF ENOW00869-1 ENOF02543-0 WARNING 1. Stop switch 2. Stop switch lock After stopping the engine: Close the air vent screw on the fuel tank cap. Disconnect the fuel connector from the engine and the fuel tank. Disconnect the battery cable, after each use.

  • Page 53: Steering

    ENGINE OPERATION Remote control type Right turn Turn the steering wheel to the right. Left turn Turn the steering wheel to the left. ENOF00891-0 ENOM00920-0 6. Steering ENOW00870-1 WARNING Sudden steering may cause passenger(s) to be thrown overboard or fall. ENOF00893-0 ENOM00050-0 Tiller handle type...
  • Page 54 ENGINE OPERATION For outboard motor model with PT or PTT ENOM00054-0 Improper trim angle (bow dips into the switch on the bottom cowl, do not oper- water) ate the switch during while cruising, or Set the thrust rod higher if the bow of control of boat may be lost.

  • Page 55: Tilt Up And Tilt Down

    ENGINE OPERATION Trim angle adjustment (Manual tilt type) 5. Remove the Snap pin and Thrust rod The transom angle adjustment as shown in the picture. 1. Stop the engine. 2. Shift into neutral position. 3. Tilt up the outboard motor. 4.
  • Page 56 ENGINE OPERATION ENOW00056-A WARNING When tilting up outboard motor with fuel joint for over a few minutes, be sure to dis- connect fuel hose, or fuel may leak, poten- tially catching fire. ENOW00057-1 CAUTION ENOF02544-0 Do not tilt up the outboard motor while engine is operating, or no cooling water may ENOM00063-1 be discharged, leading to engine seizure due...
  • Page 57 ENGINE OPERATION Tilt down The outboard motor can also be tilted up 1. Release the tilt stopper from the set- and down using the switch provided on up position while slightly tilting up the bottom cowl. outboard motor. 2. Operate the Power Tilt switch and tilt the outboard motor down until the motor touches to the thrust rod.

  • Page 58: Shallow Water Operation

    ENGINE OPERATION ENOW00054-1 CAUTION Do not over tilt the outboard motor when driving in shallow water, or air may be sucked through water inlet and sub-water inlet, potentially leading to engine overheating. ENOF00892-0 1. Power ENOF01144-0 2. Manual 1. Water inlet Manual relief valve specified tighten- 2.
  • Page 59 ENGINE OPERATION 2. Return to normal running position: Put the reverse lock lever in the tilt down position, slightly lift up the out- board motor, and then put it down. ENOF02526-0 1. Reverse lock lever 2. Tilt down position 3. Tilt up position ENOM00069-A Power Tilt type 1.

  • Page 60: Removing And Carrying The Outboard Motor

    REMOVING AND CARRYING THE OUTBOARD MOTOR ENOM00070-A 1. Removing the outboard motor ENOW00890-0 WARNING Before installing the outboard motor on the boat, hang the outboard motor with the hoist or equivalent device by attaching the engine hanger to the outboard. Use the hoist with allowable load is 150 kg (330 lbs) or above.

  • Page 61: Trailering

    REMOVING AND CARRYING THE OUTBOARD MOTOR Otherwise, engine's exterior may be dam- down on the cushion as shown in the drawing. age d or wa ter may enter th e cylinder through the exhaust port and cause engine problems. ENOF02529-0 ENOM00072-1A 3.
  • Page 62 REMOVING AND CARRYING THE OUTBOARD MOTOR ENOW00071-0 CAUTION The tilt support device supplied on your out- board motor is not intended for towing. It is intended to support the outboard motor while the boat is docked, beached, etc. When transporting a boat on a trailer with the outboard motor attached, dis- connect the fuel line from the outboard motor beforehand and keep the out-...

  • Page 63: Adjustment

    ADJUSTMENT Friction adjustment of the throttle grip ENOM00073-0 1. Steering friction can be made with the throttle adjustment screw. Tiller handle type ENOW00074-1 WARNING Do not over tighten the steering friction lever, it could result in difficult handling of the outboard motor, resulting in the loss of control causing an accident and could lead ENOF00911-1 to severe injury.

  • Page 64: Trim Tab Adjustment

    ADJUSTMENT If straight-line cruising can not be Side mount type 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 65: Multi-Function Tiller Handle Angle Adjustment

    ADJUSTMENT Angle of Multi-Function Tiller Handle ENOM01903-0 5. Multi-function tiller handle according to the number of spacers. angle adjustment Spacer [1] Spacer [2] Angle (approx) (Qty) (Qty) ENOW00985-0 WARNING Do not install or remove spacers on the 20.5 bracket with engine running. 23.5 Do not install more than 6 spacers [ 1 ].

  • Page 66: Inspection And Maintenance

    INSPECTION AND MAINTENANCE ENOM00077-1 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 maintenance as suggested in the mainte- nance schedules as follows. ENOW00077-1 CAUTION Your personal safety and that of your pas- sengers depends on how well you main-...

  • Page 67: Daily Inspection

    INSPECTION AND MAINTENANCE ENOM00079-0 1. Daily Inspection Perform the following checks before and ENOW00078-1 after use. WARNING Do not use outboard motor if any abnormal- ity is found during pre-operation check oth- erwise it could result in severe damage to the motor or severe personal injury.
  • Page 68 INSPECTION AND MAINTENANCE Item Points to Check Remedy • Make sure that steering handle and remote control is Repair Steering Devices functioning normally. • Check if the anode is securely installed. Repair if necessary Other parts • Check the anode for corrosion and deformation. Replace ENOM01905-0 Oil level checking...
  • Page 69 INSPECTION AND MAINTENANCE Wipe off engine oil well immediately if ENOM00083-B Washing outboard motor spilled and dispose of it in accordance with local fire prevention and environ- ENOW00920-0 ment protection regulations. CAUTION Do not replenish engine oil over upper limit. If overfilled, remove oil to upper When washing the outboard motor, be care- limit.
  • Page 70 INSPECTION AND MAINTENANCE 1. Fully tilt down the outboard motor. 5. Place the shift lever in the neutral position and start the engine and run 2. With the propeller removed, seal the at idle speed for 3-5 minutes. sub-water inlet with a tape to prevent air from being sucked into the water 6.
  • Page 71 INSPECTION AND MAINTENANCE ENOM00085-E ENOM00085-A Flushing hose joint Flushing by test tank ENOW00921-0 ENOW00081-1 CAUTION WARNING Do not operate the engine when flushing the Do not start engine without removing pro- outboard motor with a hose joint as this can peller, turning propeller out in the open may cause damage to the outboard motor.
  • Page 72 If you are unable to respond to the cause or the fuse continues to blow, request an authorized Tohatsu dealer for inspection. ENOF02532-0 1. Stop the engine and disconnect the 1.

  • Page 73: Periodic Inspection

    INSPECTION AND MAINTENANCE ENOM01106-1 2. Periodic Inspection It is important to inspect and maintain your outboard motor regularly. Make sure to per- form each service at interval specified in the chart below. Maintenance intervals are determined by the number of hours outboard motor has been used or number of months, whichever comes first.
  • Page 74 INSPECTION AND MAINTENANCE Inspection intervals First 20 Every 50 Every 100 Every 200 Every 400 Description Inspection procedure Remarks hours or 1 hours or 3 hours or 6 hours or 1 hours or 2 month months months year year Propeller Check/Replace if necessary.
  • Page 75 INSPECTION AND MAINTENANCE ENOM00091-A ENOM01906-0 Engine oil replacement To change engine oil: Be sure to use recommended engine oil. ENOW00091-1 1. Stop the engine and leave it in a verti- CAUTION cal position over 5 minutes. You may be injured due to high engine tem- 2.
  • Page 76 INSPECTION AND MAINTENANCE 6. Fill the engine through the filler port ENON00920-0 Note with the recommended trapped oil to Use only recommended engine oil (See between the upper and lower limit page 33) mark on the dipstick. 7. Tighten the oil filler cap. 8.
  • Page 77 INSPECTION AND MAINTENANCE ENOM01901-0 Oil filter replacement ENOW00091-1 CAUTION You may be injured due to high engine tem- peratures if you fill engine oil just after oper- ENOF00094-0 ation. Engine oil should be changed after the 1. Oil filter wrench P/N 3AC-99090-0 engine has been cooled.
  • Page 78 INSPECTION AND MAINTENANCE ENOM00093-A Fuel filters and fuel tank cleaning ENOW00093-1 WARNING Gasoline and its vapor is very flammable and can be explosive. Do not start this procedure while engine is operating or while engine is hot. ENOF01242-1 Place fuel filter away from every source of ignition such as sparks or open flames.
  • Page 79 INSPECTION AND MAINTENANCE 6. Cup ENOM00098-A Gear oil replacement 7. Indicate of Fuel Flow ENOW00076-1 ENOM00096-A WARNING Fuel filter (for fuel tank) Water or dirt in the fuel tank will cause Be sure that the outboard motor is engine performance problems. secured to transom or service stand, or Check and clean the tank at specified accidental drop or fall of outboard motor...
  • Page 80 INSPECTION AND MAINTENANCE 3. Insert the oil tube nozzle into the 4. Install the upper oil plug, and then lower oil plug hole, and fill with gear remove oil tube nozzle and install the oil by squeezing the oil tube until oil lower oil plug.
  • Page 81 INSPECTION AND MAINTENANCE 2. Remove the split pin, propeller nut ENOM00086-A Propeller replacement and washer. ENOW00084-1 3. Remove the propeller and thrust WARNING holder. 4. Apply waterproof grease to the pro- Do not install or remove propeller on the peller shaft before installing a new outboard motor with spark plug caps attached, shift in forward or reverse, propeller.
  • Page 82 INSPECTION AND MAINTENANCE Use spark plug NGK DCPR-6E. ENOM00087-A Spark plugs replacement ENOW00087-1 WARNING Do not reuse spark plug, if the insulation is damaged or sparks can leak through crack, potentially leading to electric ENOF00085-0 shock, explosion and/or fire. Do not touch spark plug(s) immediately 1.
  • Page 83 INSPECTION AND MAINTENANCE ENOM00088-1A Anode replacement A sacrificial anode protects the outboard motor from galvanic corrosion. Anode is located on the gear case, cylinder etc.. When the anode is eroded more than 1/3 of original size, replace it. ENON00029-1 Notes Never grease or paint the anode.
  • Page 84 INSPECTION AND MAINTENANCE Recommended oil ENOM00089-B Power Tilt oil checking Use automatic transmission fluid or ENOW00088-0 equivalent. WARNING Recommended oil is are as shown below. ATF Dexron III Be sure that outboard motor is secured to Air purging from the Power Trim and Tilt transom or service stand, or accidental unit.
  • Page 85 INSPECTION AND MAINTENANCE ENOM00960-0 Grease point Apply waterproof grease to the parts shown below. ENOF02549-0...

  • Page 86: Off-Season Storage

    INSPECTION AND MAINTENANCE ENOM00100-A ENOM00101-1A Engine 3. Off-season storage 1. Wash the engine exterior and flush the cooling water system thoroughly ENOW00934-0 with fresh water. Drain the water WARNING completely. Wipe off water with a cloth. Be sure to disconnect fuel connector except when operating engine.
  • Page 87 INSPECTION AND MAINTENANCE 9. Place the outboard motor in the ver- then lay the outboard motor with port side down on the cushion as shown in the tical position under a dry condition. drawing. ENOF02529-0 ENOM00950-0 Adding a fuel stabilizer When adding a fuel stabilizer additive (commercially available), first fill the fuel tank with fresh fuel.
  • Page 88 INSPECTION AND MAINTENANCE 7. Check the drained fuel for the pres- ENOM01902-0 Fuel system draining ence of water or other contaminants. ENOW00028-A If either is present, refill the vapor WARNING separator with fuel, and then drain the fuel again. Repeat this procedure For details on handling fuel, contact an until no water or other contaminants authorized dealer.

  • Page 89: Pre-Season Check

    INSPECTION AND MAINTENANCE 5. Recharge the battery once a month 7. Start the engine and warm up the to prevent it from discharging and the engine for 3 minutes in the “NEU- electrolyte from deteriorating. TRAL” position. 6. Store the battery in a dry place. 8.

  • Page 90: Cold Weather Precautions

    INSPECTION AND MAINTENANCE 3. Remove the spark plugs, and com- 2. Check the control system, gear case, pletely drain the water from the boat transom etc. engine by pulling recoil starter several 3. Return to the nearest harbor slowly times. and carefully.

  • Page 91: Troubleshooting

    TROUBLESHOOTING ENOM00109-0 If you encounter a problem, check the 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 Fuel level is low in the tank. Fuel system connection is incomplete.
  • Page 92 TROUBLESHOOTING Possible cause Defective wiring, ground, wire disconnected or loosened. Use of spark plugs not specified. Spark plug is contaminated. No sparks or weak spark. Stop switch short-circuited. Stop switch lock is not installed correctly. Battery charging defective, or rectifier malfunctions.
  • Page 93 TROUBLESHOOTING Possible cause Low compression Valve timing is not correct (Belt is stretched or installed incorrectly). Valve clearance is defective. Valve seat sealing is defective. Piston, piston ring and/or cylinder is worn excessively. Too much carbon deposition in the combustion chamber. Spark plug tightening is loose.

  • Page 94: Tool Kit And Spare Parts

    TOOL KIT AND SPARE PARTS ENOM00109-0 The followings are a list of the tools and spare parts provided with the motor. Items Quantity Remark Socket wrench 16 Socket wrench 10-13 Tool bag Socket wrench handle Pliers ± Screwdriver Emergency starter rope Spark plug NGK DCPR6E Propeller nut split pin...

  • Page 95: Propeller Table

    PROPELLER TABLE ENOM00111-0 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. 25 : 5000–6000 min (rpm) 30 : 5500–6500 min (rpm) Propeller Size (Diameter × pitch) Propeller Mark inch...

  • Page 96: Emission Control System Information

    EMISSION CONTROL SYSTEM INFORMATION ENOM01000-0 ENOM01003-0 Emission Sources Clean Air Acts of the United States and California, and Environment Canada Carbon monoxide, oxides of nitrogen and EPA, California, and Canadian regulations hy drocarbons are produce d in the require all manufacturers to provide writ- course of the combustion process.
  • Page 97 ENOM01006-0 Replacement Parts 2011. The emission control system in your Tohatsu out board motor has be en designed, built, and certified to conform with the EPA and California emission reg- ulations. Whenever requesting mainte- nance, use of Tohatsu Genuine parts is highly recommended.
  • Page 98 EQUIPPED FOR UNITED STATES AND EQUIPPED FOR UNITED STATES AND CANADA MODEL CANADA MODEL The Environmental Protection Agency TOHATSU adopts Primer bulb/hose (EPA) required portable fuel systems that assembly approved by the Environment are produced after January 1, 2011 for use Protection Agency (EPA).
  • Page 99 EMISSION CONTROL SYSTEM INFORMATION label identifies engines that meet the Air ENOM01007-0 Maintenance Resources Board’s Personal Watercraft and Out board marine engine 2001 Follow the maintenance schedule pre- exhaust emission standards. sented on page 73. Keep in mind that this Engines meeting these standards have schedule is based on the assumption that 75% lower emissions than conventional...
  • Page 100 EMISSION CONTROL SYSTEM INFORMATION Sterndrive and Inboard marine engine 2003-2008 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star-Low Emission engines. ENOF01004-0 ENOM01012-0 Four Stars-Super Ultra Low Emission The four-star label identifies engines that meet the Air Resources Board’s Stern- drive and Inboard marine engine 2009 exhaust emission standards.
  • Page 102 O W N E R’ S M A N U A L MFS 25D MFS 30D 5-4, Azusawa 3-Chome, Itabashi-Ku Tokyo 174-0051, Japan Tel: +81-3-3966-3117 Fax: +81-3-3966-0090 www.tohatsu.com...

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