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

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OWNER'S
MANUAL
M 25H
30H
40C
OB No.003-11055-5

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Summary of Contents for TOHATSU M 25H

  • Page 1 OWNER’S MANUAL M 25H OB No.003-11055-5...
  • 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 25H, 25H EF, 25H EP MODEL 25H EF 25H EP Item Overall Length mm (in) 884 (34.8) 600 (23.6) Overall Width mm (in) 412 (16.2) 355 (14.0) 1,124 (44.3) · 1,251 (49.3) · 1,378 (54.3) Overall Height S·L·UL mm (in) 435 (17.1) ·...
  • Page 11 SPECIFICATIONS 30H, 30H EF, 30H EP MODEL 30H EF 30H EP Item Overall Length mm (in) 884 (34.8) 600 (23.6) Overall Width mm (in) 412 (16.2) 355 (14.0) 1,124 (44.3) · 1,251 (49.3) · 1,378 (54.3) Overall Height S·L·UL mm (in) 435 (17.1) ·...
  • Page 12 SPECIFICATIONS 40C 40C EF, 40C EP MODEL 40C EF 40C EP Item Overall Length mm (in) 919 (36.2) 600 (23.6) Overall Width mm (in) 415 (16.3) 355 (14.0) 1,118 (44.0) · 1,245 (49.0) · 1,372 (54.0) Overall Height S·L·UL mm (in) 435 (17.1) ·...

  • Page 13: Names Of Parts

    NAMES OF PARTS 25H, 30H Tilt Handle Oil Plug (Lower) Stop Switch Top Cowl Oil Plug (Upper) Choke Knob Cooling Water Check Port Drive Shaft Housing Fuel Connector Water Plug Thrust Rod Primer Bulb Reverse Lock Lever Clamp Bracket Fuel Connector Anti Ventilation Plate Clamp Screw Fuel Tank Cap...
  • Page 14 NAMES OF PARTS 25H EF, 30H EF Tilt Handle Oil Plug (Upper) Choke Knob Top Cowl Drive Shaft Housing Main Switch Cooling Water Check Port Thrust Rod Fuel Connector Water Plug Clamp Bracket Primer Bulb Reverse Lock Lever Clamp Screw Fuel Connector Anti Ventilation Plate Throttle Grip...
  • Page 15 NAMES OF PARTS 25H EP, 30H EP Tilt Handle Oil Plug (Lower) Primer Bulb Top Cowl Oil Plug (Upper) Fuel Connector Cooling Water Check Port Drive Shaft Housing Fuel Tank Cap Water Plug Thrust Rod Air Vent Screw Reverse Lock Lever Clamp Bracket Fuel Pick up Elbow Anti Ventilation Plate...
  • Page 16 NAMES OF PARTS Tilt Handle Oil Plug (Upper) Choke Knob Top Cowl Drive Shaft Housing Fuel Connector Cooling Water Check Port Thrust Rod Primer Bulb Water Plug Clamp Bracket Fuel Connector Reverse Lock Lever Clamp Screw Fuel Tank Cap Anti Ventilation Plate Throttle Grip Air Vent Screw Trim Tab...
  • Page 17 NAMES OF PARTS 40C EF Tilt Handle Oil Plug (Upper) Stop Switch Top Cowl Drive Shaft Housing Choke Knob Cooling Water Check Port Thrust Rod Main Switch Water Plug Clamp Bracket Fuel Connector Reverse Lock Lever Clamp Screw Primer Bulb Anti Ventilation Plate Throttle Grip Fuel Connector...
  • Page 18 NAMES OF PARTS 40C EP Tilt Handle Oil Plug (Upper) Fuel Connector Top Cowl Drive Shaft Housing Fuel Tank Cap Cooling Water Check Port Thrust Rod Air Vent Screw Water Plug Clamp Bracket Fuel Pick up Elbow Reverse Lock Lever Clamp Screw Fuel Tank Anti Ventilation Plate...

  • Page 19: Installation

    INSTALLATION Transom matching 1. Mounting the outboard motor on boat 1 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 Most boats are rated and certified met due to the shape of the bottom in terms of their maximum allowable of your boat, please consult your...
  • Page 20 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 unsafe conditions such as poor water in a proper attitude. Check maneuverability, lack of control or fire.

  • Page 21: Installing The Remote Control Devices

    Spring Ball Washer Cable outer holder groove When using other than Tohatsu’s genuine remote control box, DO NOT select the one without neutral safety switch that Throttle cable prevents in-gear start. Use of remote control box without Shift side..Fit the sleeve B guide...
  • Page 22 INSTALLATION 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°...
  • Page 23 INSTALLATION 3 Connecting the Cord Assembly 40C EP (Wiring Harness) 1 Fitting of Holder Cap and Grommet Pass the cord assembly from the Throttle side remote control through the hole in • Take out the grommet from the the bottom cowl and connect the advancer arm side of the bottom electric terminals and then clamp cowl.
  • Page 24 INSTALLATION 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 holder and then connect the holder cap to the ball joint of the starter lock arm.

  • Page 25: Installing The Battery

    INSTALLATION 3 Connecting the Cord Assembly 3. Installing the battery (Wiring Harness) Pass the cord assembly from the 1 Place the battery box in a convenient remote control through the hole position away from possible water in the lower cowl and connect the spray.
  • Page 26 INSTALLATION 2 Connect the positive lead (+) to the ������� positive terminal (+) of the battery, and then connect the negative lead Battery generates explosive hydrogen gas. Be sure to: (−). When disconnecting the battery • Charge the battery in a well- always remove the negative lead (−) ventilated place.

  • Page 27: 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 28 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 29: Recommended Engine Oil

    PRE-OPERATING PREPARATIONS 2. Recommended engine oil Note U s e a g e n u i n e e n g i n e o i l o r Use of engine oils that do not meet recommended one. Refer to your these requirements will result in reduced engine life, and other engine problems.
  • Page 30 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 31: Break-In

    PRE-OPERATING PREPARATIONS 3. Break-in Your new outboard motor and lower ������� unit require break-in for the moving c o m p o n e n t s a c c o r d i n g t o t h e Operating the outboard motor without conditions described in the following break-in can shorten service life of the...

  • Page 32: Engine Operation

    ENGINE OPERATION 2 Attach the fuel connector to the Before starting engine connector. The arrow mark on the primer bulb Before starting engine for the first time should be facing the engine. after reassembling engine or off-season storage, disconnect stop switch lock and pull the starter handle completely out approximately 10 times in order to prime the oil pump.
  • Page 33 ENGINE OPERATION 5 Turn the throttle grip until the mark ■ 25H, 30H, 40C and EF type 4 Place the shift lever in the Neutral on the grip faces the triagular mark position. on the steering handle. Be sure that the shift is in Neutral Throttle grip when starting the engine.
  • Page 34 ENGINE OPERATION ■ 25H, 30H, 40C type ■ EF type 7 Push the starter button. Starting Guideline for 25H, 30H 8 Release pushing the button when Temperature Starting procedure the engine has started. Over 25°C Turn the throttle grip to (77°F) original position, pull the choke knob and recoil starter...
  • Page 35 ENGINE OPERATION 9 Returns the Free accel lever to close ■ EP type position. 4 Insert the main switch key. 5 Set the control lever in the Neutral Lock button position. Neutral (N) START Fully open Control lever Fully closed Free accel lever Main switch Push to...

  • Page 36: Warming Up The Engine

    ENGINE OPERATION If the recoil starter fails to operate 2. Warming up the engine • Remove the top cowl and the recoil starter. Wrap a rope around the Warm the engine at low engine speeds starter pulley then pull quickly to for about three minutes.

  • Page 37: Forward And Reverse

    ENGINE OPERATION 3. Forward and reverse ������� Be sure to stop engine immediately ������� if cooling water check port is not discharging water, and check if cooling Before shifting into forward or reverse, water intake is blocked. Operating make sure that boat is properly engine could lead to overheating moored and outboard motor can be potentially leading to engine damage.
  • Page 38 ENGINE OPERATION ■ 25H/30H/40C and EF type Lock Revese lock lever Neutral Reverse Forward Shift lever Release ������� Severe damage, and personal injury, may occur if shifting at high engine speed. Engine must be in the slow idle position before shifting is attempted. Forward Turn the throttle grip to reduce engine speed.
  • Page 39 ENGINE OPERATION ������� Note • Before moving the Shift Lever to Frequent shifting to forward or reverse Reverse, make sure the Reverse can accelerate wear or degradation of Lock is engaged (in up position). parts. In such case, replace gear oil earlier than the period specified.

  • Page 40: Stopping

    ENGINE OPERATION 4. Stopping Note The control lever is inoperative unless 25H, 30H, 40C and EF type the free accel lever is in the fully closed position. Choke knob Note Reduce the engine speed when the control lever is in Neutral and do not increase the engine speed unnecessarily.

  • Page 41: Trim Angle

    ENGINE OPERATION EP type 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 START anti ventilation plate to run parallel to the water surface during operation.

  • Page 42: Tilt Up, Tilt Down And Shallow Water Operation

    ENGINE OPERATION 6. Tilt up, tilt down and shallow water operation ������� When tilting up or down, be careful not to place your hand between the swivel bracket and the stern bracket. Be sure to tilt the outboard motor down slowly. Thrust rod Note Higher...
  • Page 43 ENGINE OPERATION ■ Shallow water operation ������� ������� • Do not put hand or finger in between outboard motor body and clamp bracket when adjusting trim During shallow water operation, be angle to prevent injury in case the careful not to place your hand between outboard motor body falls.
  • Page 44 ENGINE OPERATION 2 Return to normal running position: ������� Put the reverse lock lever in the tilt down position, slightly lift up the Do not overtilt outboard motor when driving shallow water, or air outboard motor, and then put it may be sucked through subwater down.

  • Page 45: Removing And Carrying The Outboard Motor

    REMOVING AND CARRYING THE OUTBOARD MOTOR 1. Removing the outboard motor 3. Storing the outboard motor 1 Stop the engine. Outboard motor should be stored in a 2 Disconnect the fuel connector, vertical position. the remote control cables and the battery cords from the outboard Note motor.

  • Page 46: Trailering

    TRAILERING ������� ������� Do not go under outboard motor tilted When trailering the outboard motor up even if it is supported by support should be in a vertical (normal running) bar, or accidental fall of outboard motor position, fully down. Trailering in the could lead to severe personal injury.

  • Page 47: Adjustment

    ADJUSTMENT 1. Steering friction 2. Remote control lever load The steering friction can be adjusted (Throttle friction adjustment screw) in accordance with your preference by To adjust the load of the remote turning the steering adjusting bolt. control lever, turn the throttle friction adjustment screw on the front of the remote control.

  • Page 48: Trim Tab Adjustment

    ADJUSTMENT ������� 3. Trim tab adjustment • Inappropriate adjustment of trim If straight-line cruising can not be tab could cause steering difficulty. achieved, adjust the trim tab located After installing or readjusting trim under the anti-ventilation plate. tab, check if steering load is even. •...

  • Page 49: Inspection And Maintenance

    INSPECTION AND MAINTENANCE 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 maintenance schedules that follow. ������� • Your personal safety and that of your passengers depends on how well you maintain your outboard motor.

  • Page 50: 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. Item Points to Check Action...
  • Page 51 INSPECTION AND MAINTENANCE Washing outboard motor ■ Use flushing attachment. If outboard motor is used in salt water, 1 Remove propeller (refer to Propeller brackish water or water with a high Replacement). Remove the water acidic level, use fresh water to remove plug from the outboard motor, and salt, chemicals or mud from exterior screw in the flushing attachment.
  • Page 52 INSPECTION AND MAINTENANCE 1 Remove the split pin, propeller nut and washer. (and stopper for 40C) Flushing plug 2 Remove the propeller and thrust holder. 3 A p p l y g e n u i n e g r e a s e t o t h e propeller shaft before installing a new propeller.
  • Page 53 INSPECTION AND MAINTENANCE ������� Note Do not hold propeller with hand(s) When inspecting the plug, always when loosening or tightening propeller clean the gasket surface and use a nut. Put a piece of wood block new gasket. Wipe off any dirt from the between propeller blade and anti threads and screw in the spark plug to ventilation plate to hold propeller.
  • Page 54 INSPECTION AND MAINTENANCE Replacing the anode A sacrificial anode protects the outboard motor from galvanic corrosion. Anode is located on the gear case, clamp bracket and the cylinder. When the anode is eroded more than 2/3, replace it. Notes • Never grease or paint the anode. •...

  • Page 55: 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 56 INSPECTION AND MAINTENANCE Cleaning the fuel filters and the fuel tank Fuel filters are provided inside the fuel tank and engine. ������� Gasoline and its vapors are very flammable and can be explosive. • Do not start this procedure while Carburetor Fuel filter engine is operating or hot even...
  • Page 57 INSPECTION AND MAINTENANCE Replacing gear oil ������� • Be sure that outboard motor is secured to transom or service stand, or accidental drop or fall of outboard motor could lead to severe personal injury. • Be sure to lock outboard motor if it is tilted up, or accidental fall of outboard motor could lead to 3 Install the upper oil plug, and then...

  • Page 58: Off-Season Storage

    INSPECTION AND MAINTENANCE over several times while feeding the 3. Off-season storage oil into it and make sure it is evenly distributed. Before you put your outboard motor 5 Change the gear oil in the gear in storage, it is a good opportunity to case.

  • Page 59: Pre-Season Check

    INSPECTION AND MAINTENANCE 4. Pre-season check Specific Terminal Charge Gravity at 20 °C Voltage (V) Condition 1 Check that the shift and throttle Fully 1.120 10.5 discharged function properly. (Be sure to turn the propeller shaft 1.160 11.1 1/4 charged when checking the shift function or else 1.210 11.7...

  • Page 60: Motor Submerged In Water

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

  • Page 61: Checking After Striking Underwater Object

    INSPECTION AND MAINTENANCE 7. Checking after striking underwater object S t r i k i n g t h e s e a b o t t o m o r a n u n d e r w a t e r o b j e c t m a y s e v e r e l y d a m a g e t h e o u t b o a r d m o t o r .

  • Page 62: 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 63 TROUBLESHOOTING Possible cause Loose battery terminal connection, corrosion ● EP and EF Discharged battery ● types Main switch trouble ● Lock plate not fitted to stop switch ● Disconnection of wire or loose ground connection ● Insufficient battery capacity, loose terminal EP and EF ●...

  • Page 64: Tool Kit And Spare Parts

    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 10 X 13mm Service Tools Socket Wrench 21mm Socket Wrench Handle Straight Edge Screwdriver Rope...

  • Page 65: Optional Accessories

    OPTIONAL ACCESSORIES OPTIONAL ACCESSORIES Speedometer (50MPH) Tachometer unit kit Speedometer Flushing plug (75MPH) Voltmeter Extension cord for light (Lights are available on the market.) Hour Meter (engine operation hour counter) Clutch lever reverse lock kit Tachometer...
  • Page 66 OPTIONAL ACCESSORIES Drag link spacer Propeller Drag link ass’y (standard : EP type) Twin remote control Genuine gear oil (500mL) Turnbuckle plate Touch-up Paint Twin remote control turnbuckle ass’y Genuine Engine Oil (0.4L, 1L, 4L, 20L)

  • Page 67: 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. 25H 5,000 to 6,000 rpm 30H 5,150 to 5,850 rpm 40C 5,200 to 5,800 rpm 25H, 30H Propeller Size...
  • Page 68 M E M O...
  • Page 69 M E M O...
  • Page 70 M E M O...
  • Page 72 OWNER’S MANUAL TOHATSU CORPORATION 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 003-11055-5 1107NB Printed in Japan...

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