TOHATSU M 2.5A 2 Owner's Manual
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TOHATSU M 2.5A 2 Owner's Manual

TOHATSU M 2.5A 2 Owner's Manual

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O W N E R' S
M A N U A L
トーハツ船外機 オーナーズマニュアル
Original instructions
M 2.5A
M 3.5A
M 3.5B
OB No.003-11045-DBB1
2
2
2
EN

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Summary of Contents for TOHATSU M 2.5A 2

  • Page 1 O W N E R’ S M A N U A L トーハツ船外機 オーナーズマニュアル Original instructions M 2.5A M 3.5A M 3.5B OB No.003-11045-DBB1...
  • 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 ENOM00113-1 DECLARATION OF CONFORMITY (DoC) This product conforms to certain portion of the European Parliament directive and UK Regulations. DoC contains the following information; Name and Address of the manufacturer, EU - notified body, EU - authorized repre- sentative, and UK - approved body. Applied community directives and regulations Reference standard Description of the product.
  • 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

    CONTENTS 1. GENERAL SAFETY INFORMATION ........10 2.
  • 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 M2.5A2 M3.5A2 M3.5B2 Type Transom heights Tiller Handle Remote Control Separate fuel tank Integral fuel tank Shifting Manual tilt *1: Option ENOM00811-B MODEL NAME EXAMPLE M3.5B2S Product genera- Model description Horse power Minor change Shaft length tion S= Short 15 in A and up...
  • Page 13 1.85 (13 : 24) 2.15 (13 : 28) Operator Sound Pressure 81.8 (ICOMIA 39/94) dB (A) Hand Vibration Level (ICOMIA 38/94) m/s Remark: Specifications are subject to change without notice. Tohatsu outboard is power rated in accordance with ISO8655 (propeller shaft output).

  • Page 14: Parts Name

    PARTS NAME ENOM01301-0 2.5A2, 3.5A2, 3.5B2 ENOF02002-0 Air Vent Screw Shift Lever(3.5B2 only) Tilt Stopper Fuel Tank Cap Handle Grip Stop Switch Top Cowl Carring Handle Carburetor Cover Plug Cap Cover Clamp Screw Chork Lever Fuel Cock Thrust Rod Drive Shaft Housing Cooling Warter Check Port Oil Plug (Upper) Grommet (3.5B2 only)

  • Page 15: Label Locations

    LABEL LOCATIONS ENOM00019-A Warning label locations 4, 5 ENOF02003-1 1-1. UNDER PRESSURE FUEL SPRAY MAY Read owner's manual. OCCUR (See page20, 25). 1-2. (See page 32). Engine stop switch ENOF02050-0 314X67531-3 HOT SURFACE Can cause burns. Do not touch. 3GR-76191-0...
  • Page 16 LABEL LOCATIONS Read owner's manual. 3F0X72185-0 HOT SURFACE Can cause burns. Do not touch when operating or immediately after the engine has stopped. ELECTRICAL SHOCK HAZARD High voltage can cause severe electri- cal shock. Do not touch electrical components such as ignition coil or spark plug cord when starting or while the engine is in operation.
  • Page 17 LABEL LOCATIONS ENOM01001-0 Serial number label locations CAN ICES-2 / NMB-2 ENOF02048-3 1. Model code(Model name) 2. Serial No. 3. Rated power 4. Dry mass weight 5. Manufacture name 6. Manufacture address 7. Authorised representative 8. Authorised representative address Description of serial number year code Last two digits of alphabet represent production year as below.

  • Page 18: Installation

    INSTALLATION Keep the outboard motor in a vertical ENOM00024-B 1. Mounting the outboard position when mounting. motor on boat ENOW00006-1 WARNING Most boats are rated and certified for their maximum allowable horsepower, as shown on the boat’s cer tification plate. Do not equip your boat with an outboard motor that exceeds this limit.
  • Page 19 INSTALLATION ENOM00026-0 ENOM00831-0 Transom matching Mounting the outboard motor Be sure that the anti ventilation plate of 1. Set the outboard motor to appropri- the outboard motor is 30–50 mm (1.2–2 ate position. in) below the bottom of hull. 2. Tighten the clamp screws by turning If the above condition cannot be met due their handles.

  • Page 20: 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 21: Engine Oil Recommendation

    PRE-OPERATING PREPARATIONS ENOW00018-1 Fuel by Oil Mixing (25:1, 50:1) WARNING Fuel leakage can cause fire or explosion, 1.0L (25:1) 25 : 1 potentially leading to severe injury or loss of life. Ever y par t of fuel system should be 0.5L (25:0.5) 0.4L...

  • Page 22: Fuel Filling

    PRE-OPERATING PREPARATIONS screw when it is loose or open. Leaking of gasoline is a may lead to a dangerous fire hazard. ENOW00028-1 WARNING Consult an authorized dealer for details on handling gasoline, if necessary. Gasoline and its vapor are very flammable and can be explosive.

  • Page 23: Break-In

    PRE-OPERATING PREPARATIONS assembly may cause a fuel leak, possibly leading to fire or explosion. Dispose aged or contaminated gasoline in accordance with local regulations. ENOW00029-1 WARNING When opening fuel tank cap, be sure to fol- low the procedure described below. Fuel could blast out if the fuel tank cap is opened by using another procedure when internal ENOF02008-0...
  • Page 24 PRE-OPERATING PREPARATIONS ENOM01004-0 Fuel mix ratio for break-in 1–10 10 min – After 3–5 hrs Gasoline 25: Genuine Engine Oil 1 3 hrs 5 hrs Less Less Full ENOW00940-0 Throttle Idle than 1/2 than 3/4 throttle Position CAUTION throttle throttle available During the break-in period, never run the Approx.

  • Page 25: Engine Operation

    ENGINE OPERATION ENOM00042-0 Before starting ENOW00022-B CAUTION Be sure to fill the engine before star ting engine. (To properly fill the engine with oil ENOF02007-0 follow the instructions. See page 21) 1. Two turns the air vent screw 2. Fuel tank cap 2.

  • Page 26: Starting The Engine

    ENGINE OPERATION 2. Run at idling only ENOM00045-D 3. Remove the propeller 2. Starting the engine (See page 47) ENOW00979-0 WARNING Before starting the engine, make sure that boat is properly moore d and outboard motor can be steering fully to right and left. Make sure that no swimmer(s) is around of the boat.
  • Page 27 ENGINE OPERATION 1. Be sure to install the stop switch lock 3. Set the throttle lever to the Start to the stop switch, and attach the position. stop switch lanyard securely to the operator or to the operator's PFD (Personal Flotation Device.) ENOF02016-0 1.
  • Page 28 ENGINE OPERATION 5. Pull the starter handle slowly until you 7. Make sure that water is being dis- feel engagement, keep pulling till you charged from the cooling water check feel less resistance. Then pull it port. quickly. Repeat the procedure until the outboard motor is started.

  • Page 29: Warming Up The Engine

    ENGINE OPERATION ENOF02021-0 9. Once the outboard motor is started, do not reinstall recoil starter and top cowl. ENOM00043-C ENOF02019-0 3. Warming up the engine 2. Remove the three bolts fastening the recoil starter. ENOW00932-1 3. Remove the recoil starter. CAUTION Be sure to check that cooling water is com- ing out of the cooling water check por t...

  • Page 30: Forward, Reverse, And Acceleration

    ENGINE OPERATION ENOM00044-B ENOW00861-1 Engine speeds WARNING Idling speed after warming up. Trolling speed Idling speed Do not shift at high boat speed, or control Model (in Forward) (in Nutral) may be lost, fall down or causing passen- 1,100 min ger(s) to be thrown overboard.

  • Page 31: Stopping The Engine

    ENGINE OPERATION ENOW00865-1A CAUTION Do not force to shift when the throttle lever is not in the fully closed position, otherwise, steering system and/or shifting mechanism may be damaged. ENOW01303-0 Forward (3.5B2 only) ENOF02024-0 Acceleration The speed is controlled by operating the throttle lever.
  • Page 32 ENGINE OPERATION 1. Lower the throttle lever in order to 1. Fuel cock 2. Air vent screw the slow position. Emergency engine stopping Remove stop switch lock to stop the engine. ENOF02026-0 1. Throttle lever 2. Fully closed 2. Put the shift lever in the Neutral posi- tion.

  • Page 33: Steering

    ENGINE OPERATION ENOM00920-0 ENOW00044-1A 6. Steering WARNING Excessive trim up or down may cause unsta- ENOW00870-1 ble boat operation, loss of control that may WARNING leads to accident during cruising. For manual tilt model, If you feel the trim Sudden steering may cause passenger(s) to is improperly positioned, stop the boat be thrown overboard or fall.

  • Page 34: Tilt Up And Down

    ENGINE OPERATION ENOM00054-0 Improper trim angle (bow dips into the water) Set the thrust rod higher if the bow of the boat is below horizontal. ENOF01612-0 1. Push in ENOF00053-0 2. Pull out 5. Reinstall the thrust rod in the desired Manual Tilt type position securely.
  • Page 35 ENGINE OPERATION ENON00921-1 ENOM01304-0 Note Outboard motor position in tilt up When the outboard motor is in the tiltup After use, leave the outboard motor upright for a minute to drain the water position, the tilt handle side must be in from inside the engine.
  • Page 36 ENGINE OPERATION ENOM00223-A Tilt down 1. Fully tilt up the outboard motor. 2. Pull out the tilt stopper. 3. Gently tilt down the outboard motor. ENOF02034-0 1. Tilt stopper...

  • Page 37: Removing And Carrying The Outboard Motor

    REMOVING AND CARRYING THE OUTBOARD MOTOR ENOM00070-B ENOW00066-1 1. Removing the outboard CAUTION motor Do not give a shock to an outboard motor during transportation. ENOW00064-1 Do not carry or store outboard motor in CAUTION any of positions described below. Otherwise, engine's exterior may be dam- Engine may be hot immediately after opera- age d or wa ter may en ter th e cylinder...

  • Page 38: Traillering

    REMOVING AND CARRYING THE OUTBOARD MOTOR fully down. Trailering in the tilted position ENON00021-3 Note may cause damage to the outboard motor, boat, etc. If the outboard motor must be laid down, If trailering with outboard motor fully down be sure that fuel is completely drained, is not available (the gear case skeg is too then lay the outboard motor with port side close to the road in a vertical position), fix...

  • Page 39: Adjustment

    ADJUSTMENT ENOM00073-E 1. Steering friction ENOW00978-0 WARNING Steering may be difficult when steering fric- tion adjustment screw is over tightened, it may also result in loss of control causing an accident and could lead to severe injury. ENON00949-0 Note The steering friction adjustment screw is used to adjust the friction load of the steering.

  • Page 40: 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 41: Daily Inspection

    INSPECTION AND MAINTENANCE ENOM01305-0 1. Daily Inspection Perform the following checks before and ENOW00078-0 after use. WARNING Do not use outboard motor if any abnormal- ity is found during pre-operation check or it could result in severe damage to the motor or severe personal injury.
  • Page 42 INSPECTION AND MAINTENANCE ENOM00083-0 ENOM00085-B Washing outboard motor Flushing attachment (3.5B2 only) 1. Tilt down the outboard motor. ENOW00081-1 2. Remove the water plug from the drive WARNING shaft housing, and screw in the flush- Do not start engine without removing pro- ing attachment.
  • Page 43 INSPECTION AND MAINTENANCE ENOM00085-A Flushing by test tank ENOW00036-1A CAUTION When starting the outboard motor in the test tank, make sure that: 1. Water level is at least 10 cm (4 in.) above the anti-ventilation plate to avoid over- heating of the engine. 2.

  • Page 44: 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 45 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. Place fuel filter away from every source of ignition such as sparks or open flames.
  • Page 46 INSPECTION AND MAINTENANCE 2. Remove the oil plugs (lower and 4. Install the upper oil plug, and then upper), and completely drain the gear remove oil tube nozzle and install the oil into a pan. lower oil plug. Oil plug specified tightening torque ·...
  • Page 47 INSPECTION AND MAINTENANCE 2. Propeller ENOM00232-C Propeller replacement 3. Split pin 2. Remove the shear pin from the shaft. ENOW00084-1 3. Apply waterproof grease to the pro- WARNING peller shaft before installing a new Do not install or remove propeller on the propeller.
  • Page 48 INSPECTION AND MAINTENANCE ENON00028-1 Note Spark plug tightening torque: 27.0 Nm (20.0 ft-lb) [2.7 kgf-m] If a torque-wrench is not available when you are installing a spark plug, tighten it 1/4 to 1/2 a turn past finger-tight. Have the spark plug adjusted to the correct torque as soon as possible with a torque-wrench.
  • Page 49 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 50 INSPECTION AND MAINTENANCE ENOM00960-0 Grease point Apply waterproof grease to the parts shown below. ENOF02044-0...

  • Page 51: Off-Season Storage

    INSPECTION AND MAINTENANCE 3. Remove the spark plug and put a tea- ENOM00100-A 3. Off-season storage spoon of engine oil or spray storage oil into the combustion chamber ENOW00097-0 through the spark plug holes. WARNING 4. Pull the ricoil starter several times to lubricate inside the cylinder.
  • Page 52 INSPECTION AND MAINTENANCE 2. Follow the instructions on the label ENOW00066-1 when adding the fuel stabilizer addi- CAUTION tive. Do not carry or store outboard motor in any 3. After adding the additive, let the out- of positions described below. board motor run in water for 10 min- Otherwise, engine's exterior parts may be utes to make sure any old fuel in the...

  • Page 53: Pre-Season Check

    INSPECTION AND MAINTENANCE 1. Close the fuel cock. 7. Check the drained fuel for the pres- ence of water or other contaminants. If fuel is contaminated, reassemble the outboard motor, refill the carbu- retor with fuel, and then drain the fuel again.

  • Page 54: Submerged Outboard Motor

    INSPECTION AND MAINTENANCE ENOM00105-D ENOM00107-A 5. Submerged outboard motor 7. Striking underwater object ENOW00098-0 ENOW00935-0 CAUTION CAUTION Do not attempt to start submerged outboard Striking the sea bottom or an underwater motor immediately after it is recovered, or object may severely damage the outboard engine could be severely damaged.

  • Page 55: Troubleshooting

    TROUBLESHOOTING ENOM01109-0 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 Empty fuel tank Incorrect connection of fuel system Air entering fuel line Deformed or damaged fuel pipe Closed air vent on fuel tank...

  • Page 56: Tool Kit And Spare Parts

    TOOL KIT AND SPARE PARTS ENOM01308-0 The followings are a list of the tools and spare parts provided with the motor. Name Quantity Remark Tool bag Pliers Socket wrench 10 × 13 mm Service tools Socket wrench 21 mm Socket wrench handle Screwdriver (Phillips-type Adapter-type and flat head)

  • Page 57: Propeller Table

    PROPELLER TABLE ENOM01108-1 To ensure optimum performance, the propeller should match the boat type and its load. Use a genuine propeller. When selecting propeller, make sure that RPM stays in the maximum operating range of engine at wide open throttle. 2.5A2: 3800–5200 min (rpm) 3.5A2/3.5B2: 4200–5300 min...
  • Page 60 O W N E R’ S M A N U A L M 2.5A M 3.5A M 3.5B 5-4, Azusawa 3-Chome, Itabashi-Ku Tokyo 174-0051, Japan Tel: +81-3-3966-3117 Fax: +81-3-3966-0090 www.tohatsu.com...

This manual is also suitable for:

M 3.5b 2M 3.5a 2

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