Documente Academic
Documente Profesional
Documente Cultură
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FOREWORD
To get the maximum
amount of pleasure and performance
out of an
motor it IS important
that you understand the functions of
the mechanism
and learn to operate the controls with ease and
confidence.
This operatmg manual will explain the construction
of the
TOHATSU
outboard motor and how to carry out periodical inspection.
As TOHATSU
follows a policy of continuous product improvement,
it
reserves the right to make changes to specifications
without prior
notice. For further informatmn
please contact TOHATSU
dealers or
TOHATSU
distributors.
outboard
TOHAT5Ll
CORPORATION
CONTENTS
Page
1. SPECIFICATIONS
2.
1)
MAIN
Model
PARTS
M40C
/
2) Model M40CEF
-4
3)
Model
M40CEP
M40CEP
3.
3-I.
INSTALLATION
Mounting
height
engines so that the anti-cavitation
30 - 50 mm (1.2 - 2) lower than
of the boat by (30 - 50 mm1 (Fig. 21.
(3) Tighten
engines to boat by cramp screw
handle and bolt of engine bracket. Tighten
engines to boat to prevent loss. (Fig. 31
Ant,-cavitation plate
(4)
Tilt
angle
The outboard
motor
Choose
appropriate
is adjustable
its tilt angle depending
on stern
tilt angle of the motor
that the anti-cavitation
running.
aProper
tilt
When
the
zontal
running,
of the thrust
is proper.
improper
tilt
Set
the
lower.
If
is holi-
while
a position
rod
angle
boat
angle
thrust
a bow
rod
of
a boat
is rising,having
heavy
pitching
or
straight
running,
the
unstable
thrust
rod
the
thrust
Set
UPPer
If a bow
goes
set
upper.
under
the
ret
lower.
rod
of
a boat
a wave,
thrust
rod
condition.
face while
3-2.
Installing
the remote
Erplanarion
of rlght hand
control
Remme
device
Conrro,
BOX is written
Shift Remme
I
Throttle Remore Control Cable
Cable
Fitting
of remote control
10
cable to engine
lever to Neutral with free accel lever is in the throtdeclosed
Position.
Pass throttle cable through hole provided on the lower motor cover advancer arm side.
Install the holder cap of end tip of the throttle cable on the ball joint.
Fix the throttle cable by cable clip using groove of the cable.
Install the grommet on the motor cover lower.
(1)
Fitting
of Cord Assembly
Assembly
from
the
Remote
Control
Box
through
the
Motor
Cover
Lower
and connect
terminals
referring
drawing
right.
Fix the Cord Assembly
by a
clamp.
11
3.
12
on kinds
~~5s ~eadwirs
3.5.
(11
Mounting
Locate
away
the
the
battery
battery
from
fasten
both
shake
loose.
box
possible
the
in a convenient
spray
box
and
position
damage.
battery
Securely
so they
do not
(21
Connect
the
positive
lead
terminal
(+)
of the
battery.
the
first.
] The
negative
battery
battery
capacity
is 70AH
at 12V.
lead
always
After
on the
circuits.
(6).
When
the
terminal
to
and
remove
connecting
positive
(+I
peace
(+I
the
positive
then
connect
disconnecting
negative
a protective
to
prevent
the
lead
(-1
cover
short
Note:
(1)
Use battery
(2)
Make
sure
trapped
If
(4)
fail
Be sure
If
they
will
(51
Keep
the
sufficient
length.
battery
motor
leads
and
are
boat
not
when
etc.
leads
may
having
that
between
turning.
(3)
leads
are
incorrectly
connected,
the
starter
to operate.
to connect
are
(+) and
misxonnected.
l-1
leads
charging
correctly.
system
be damaged.
battery
fully
charged
at all
times.
13
3-6.
genuine
end
[II Fuel
(1) Fuel is mixed in the ratio 50 parts gasoline
and 1 part of Tohatsu genuine engine oil.
A new outboard
mufur should be broken-in
by running
for the first 10 hours on fuel
having a 2O:l rmxmg ratm (gasohne and
j engineoill.
1
(21 When ordinary two cycle engine oil is used,
fuel should be mixed in the ratio of either
2O:l or 15:l for breaking-in period.
(3) The use of poor quality gasoline and engine
oil will shorten the life of an engine and also
cause poor starting and other troubles. Be sure
to use only high quality gasoline and Tohatsu
genuine engine oil.
(4) Check that a tank contains
a sufficient
amount of fuel before starting for the days
operation.
14
FOR TOHATSU
OUTBOARD
Fuel Gasolin
Premium (super) gasoline is highly recommended
for TOHATSU
Outboard motors.
Fuel gasoline should be a minimum pump posted
octane rating of 87 (91 by research octane rating).
Gasoline containing
alcohole, methanol Imethyl),
or ethanol (ethyl), may cause:
0 Wear and damage on bearings, piston. piston
rings and cylinder liners
0 Corrosion on metal parts
0 Dererioration
of rubber parts and plastic
parts.
Note:
Engine damage resulting from the use of fuel containing such alcohl(s) is not the responsibility
of
TOHATSU,
and will not be covered under the lim.
ited warranty.
MOTORS
Engine Oil
Use genuine TOHATSU
Outboard Motor Oil.
If TOHATSU
Outboard Motor Oil is not available,
another Marine Engine Manufacturers
Outboard
Motor Oil with NMMA(BIA)
certified TC-W or TC.
W!l rating must be used to maintain theTOHATSU
Outboard Motor Warranty.
Caution
Do not mix different brands of oil.
The mixing of different brands of oil or different
kinds of oil even in same brand may cause jelling
lgell, resulting in blockage of filter screens.
This may lead to serious engine damage, due to the
lack of powerhead lubrication.
15
16
121
Break-in
Running
1)
Break-in
running
time
10 hours
4.
4-l.
111
STARTING
To start
Prsparation
ENGINE
to start
M40ClM40C
(1)
Confirm
(2)
Turn
(3)
EF type
if the shift
the
handle
tri-angle
mark
Pull
the choke
out
lever
grip
on the
is in Neutral
until
the
steering
knob
fully.
position.
bar mark
handle.
on the grip
faces
the
l-7
EP type
(2) Starting
19
20
by this emergency
4-2.
Warming
up engine
Warm
the engine
by running
at low speed for about
three
minutes.
This allows
to all parts of the engine.
Careful
warming
up will prolong
the life of the engines
Note:
If
cooling
will
running
followed
Engine
Idling
water
heating
is not
occur.
This
circulating
will
by engine
the
lubricating
oil
to circulate
over-
cause
erratic
seizure.
speeds
speed
when
warming
Model
Clutch
M40CIEFIEP
Maximum
Model
M40WEFlEP
operating
up
in
850rpm
speed
Full
Clutch
1
at full
950rpm
throttle.
throttle
5,200
off
rpm
-
range
5.800
21
4-3.
Forward
( M40CIEF
111 Forward
22
type 1
23
4-4.
Stopping
M4OCIM40C
EF type
A-5.
11) Tilt up
Move the reverse lock lever to the RELEASE
position.
Tilt up the engine and lock by using tilt lever.
25
4.6.
Shallow
(1) Shallow
water running
26
Reverse driving is to be done in trolling speed when an engine is at shallow water driving position.
Do not increase engine revolution than requiring.
To use an engine in high revolution is very dangerous, because of jumping up an engine from water.
Forward driving is to be done within engine revolution range that a propeller does not have cavitation.
4-7.
Removing
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27
5.
5-l.
ADJUSTMENTS
Adjusting
steering reSist?Jnce
5-2.
Adjusting
a trim tab
If the boat fails to run straight, adjust the trim tab which
underneath anti-cavitation
plate.
(Example-l
(Example-2)
Note:
28
29
(1)
Cleaning
with
fresh
water
Wash down engine with fresh water to remove mud and salt from body casing. Flush out the cooling system
with clean, fresh water after operating in salt or muddy water.
Take
storage
out
a propeller
for
long
from
engine
when
use a flushing
term.
This
engine
30
work
turning
should
over
be
slowly.
done
with
the
plug.
Be sure to clean
with
frssh
water
before
-AL
(2)
Changing
Worn
cause
the
or
both
ance
and
propeller
bent
poor
(31
propeller
will
engine
perform-
eventually
engine
Checking
Remove
center
new
spark
carbon
plug
from
electrode.
around
the
Replace
with
if necessary.
trouble.
l
Take
the
split
propeller
propeller
thrust
l Withdraw
l
out
remow
Before
TOHATSU
propeller
the
pin
nut
and
and
washer.
Remove
tion
spark
propeller.
the
wire
apply
to
the
peller
prevent
ignito
plug
removing
re-assembling.
GREASE
Note:
the
in
the
before
order
proto
accidents.
shaft.
31
installed
Dimensional
division (m/m)
1 pI , R;;ence
dimensions
Dimensions
of new product
51
050
Dimensions
for replacement
43
44
..
32
wrro-
(5)
Changing
(1)
Drain
gear
gear
oil
oil completely
removing
both
lower plugs.
upper
by
and
(2)
Inject
oil
plug
hole
from
upper
into
lower
until
it
oil plug.
oil
flows
I31
Replace
upper
lower
plug
ing oil
injector.
Tighten
lower
plug,
after
then
withdraw-
oil plug.
33
side
35
6.3
Treatment
before-after
store motor
is going to be re-used after
for 10 minutes.
36
motor.
6-4.
The SUBMERGED
If the
outboard
is neglected
The
motor
motor
would
or delayed,
emergency
measures
engine
from
I21
Remove
the
spark
plug
(3)
After
discharging
water
and
water
the
into
of the engine
water
may
it must
become
rusty
be immediately
and
disassembled
corroded
and
may
and
become
oiled.
If this
unstable.
include:
the
from
be submerged
all parts
11) Remove
and
in water
and wash
remove
inject
carburetor
side
water
TOHATSU
and
disperse
seawater
and mud
from
genuine
the
from
the cylinder
engine
engine
oil
the
engine
by turning
oil into
the
by turning
with
fresh
the engine
cylinder
the
engine
water.
over
by the starter
through
the
over
again
spark
rope.
plug
by recoil
holes
starter
OPE
141
After
taking
these
emergency
measures
have
your
engine
repaired
at your
TOHATSU
dealer
as soon
as
possible.
6-5.
If the
boat
perature
prevent
from
with
falls
water
the
pump
an
below
from
outboard
motor
mounted
0C. water
in the
freezing.
the lower
by turning
the
engine
is moored
for
some
cooling
water
pump
may
part of the motor
is kept
by the starter
rope
when
time
freeze
in the
it is in the
under
conditions
and damage
the
water
or discharge
tilted
where
the
air tem-
pump
impeller.
To
water
completely
up position.
37
7.
TROUBLE
SHOOTING
Possible
causes of engine troubles
are listed
For checking
and repairing
the engine.
refer
ITarT.
.. I .
k. T=.
table.
Contact
your
TOHATSU
dealer
as required.
.
.
.
.
Distorted
.
.
.
.
.
.
.
.
Improper gasoline
Excessive oil in mixture
f-
38
below.
to this
fuel
q ioe
39
8.
ATTACHMENTS
Name
TOOIS
Spare parts
Tool bag
Pliers
10 x 13 socket wrench
21 socket wrench
Socket wrench handle
Slotted-head screwdriver
Quantity
1
1
1
1
1
1
starter rope
Spark plug
1
1
Split pin
Fuel tank
Primer valve
1
1
A complete set
A complete set
A complete set
A complete set
1
Remote control
box
Remote control
parts
Drag link
fitting
Flushing
plug
Dimensions
Remarks
lOwl3mm
21 mm
1000 mm
NGK 87HS-10 or
CHAMPION
L82YC
(Gap: 1.0 mm1
9.
OPTIONAL
ACCESSORIES
..
%;,,
VI Meter
b
lamp witch
(111 TOHATSU
150 9.260
grease
d
112lTOHATSlJ
gear oil
1260 cc. 600 ccl
/l846
42
.--------J
.k,l
10.
PROPELLER
SELECTION
-
14
13
12
10
(mm)
260x352
262x322
266x296
268x267
275x252
(inch)
10.2x13.9
10.3x12.7
10.6x11.7
10.6x11.3
10.8x
dimensions:
Cl x PI
a.5
276x226
285x220
10.9x6.9
11.2x
7
290x160
Size
Note:
9.9
6.7
11.4x7.1
* marked one.
43
11.
WIRING
DIAGRAM
1. M40C TYPE
44
2. M4OCEF
TYPE
45
4. REMOTE
CONTROL
BOX
(RC3C.
RC5C)
r-
!Iif
-5
47
:i
7r
TOHATSU
CCIRPORATION
J.
93
Printed
I Japan
(Z)