TOHATSU M 40D2 User Manual

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TOHATSU M 40D2 Specifications

General

Engine Type	2-Stroke
Output	40 HP
Cylinder	2
Starting	Manual or Electric
Ignition System	CDI
Gear Ratio	2.08:1
Fuel Type	Gasoline
Shaft Length	20 inches
Oil Injection	Yes
Oil Type	TC-W3 2-stroke oil

Summary

YOUR TOHATSU OUTBOARD MOTOR

To You, Our Customer

Welcome message to the new owner of the Tohatsu outboard motor.

PRE-DELIVERY CHECK

Instructions to ensure the product was checked by a dealer before delivery.

Serial Number Recording

Serial Number Record

Space to record the outboard motor's serial number for future reference.

Warning Symbol Definitions

DANGER Symbol

Information about severe personal injury or death, and possibly property damage.

WARNING Symbol

Information about severe personal injury or death, or property damage.

CAUTION Symbol

Information about personal injury or property damage.

NOTE Symbol

Special information to facilitate use or maintenance or clarify important points.

GENERAL SAFETY INFORMATION

Safe Boat Operation

Operator responsibilities for safety and adherence to boating regulations.

Emergency Stop Switch Usage

Function and correct usage of the emergency stop switch.

Personal Flotation Device (PFD)

Requirement to wear a PFD while operating the boat.

Servicing, Parts & Lubricants

Maintenance Importance

Emphasizes proper maintenance for safe operation and longevity.

Hazardous Substance Warnings

Highlights risks from carbon monoxide and flammable gasoline.

SPECIFICATIONS

Model Features Overview

Details features and options for M40D2 and M50D2 models.

Model Name Explanation

Clarifies the meaning of model name components and codes.

Model Specific Specifications

40D2/50D2 MF Specifications

Detailed specifications for the 40D2/50D2 MF outboard motor model.

PARTS NAME

40D2MF/50D2MF Components

Diagram and list of parts for 40D2MF/50D2MF models.

PARTS NAME

40D2EFTO/50D2EFTO Components

Diagram and list of parts for 40D2EFTO/50D2EFTO models.

PARTS NAME

40D2EPO/50D2EPO Components

Diagram and list of parts for 40D2EPO/50D2EPO models.

PARTS NAME

40D2EPTO/50D2EPTO Components

Diagram and list of parts for 40D2EPTO/50D2EPTO models.

Remote Control & Fuel Tank Parts

Control Box & Fuel Tank Components

Diagram and list of components for the remote control box and fuel tank.

LABEL LOCATIONS

Warning Label Placement

Diagrams showing the locations of various warning labels on the outboard motor.

Specific Warning Labels

Safety & Operation Warnings

Labels regarding manual reading, rotating parts, high voltage, and engine oil.

Fuel & Lanyard Warnings

Labels concerning gasoline handling and stop switch lanyard security.

Serial Number Label Details

Serial Number Label Location

Diagram showing the location and details of the serial number label.

INSTALLATION

Mounting the Outboard Motor

Instructions and warnings for securely mounting the outboard motor onto a boat.

Installation Guidelines

Engine Placement and Spacing

Guidelines for engine placement relative to the boat's keel line and transom.

Installation Hardware

Mounting Bolt Procedures

Details on using mounting bolts for manual tilt and power trim types.

Power Trim & Tilt Mounting

Instructions for attaching the outboard motor using bolts for the power trim and tilt type.

Remote Control System Installation

Remote Control Box Placement

Guidance on installing the remote control box for easy operation.

Remote Control Cable Considerations

Advice on location and cable length for the remote control system.

Battery Installation Guide

Battery Installation Procedure

Instructions and warnings for safely installing the outboard motor battery.

Battery Installation Details

Recommended Battery Specifications

Information about recommended battery types and purchase advice.

PRE-OPERATING PREPARATIONS

Fuel Handling Precautions

Precautions and guidelines for handling gasoline, including rating and alcohol content.

Fuel System Preparation

Fuel Filling Procedure

Instructions and warnings for safely filling the fuel tank.

Engine Oil Recommendations

Engine Oil Selection Guide

Guidance on selecting and using the correct engine oil.

Fuel and Oil Mixing

Fuel and Oil Mixing Ratios

Visual guide and procedures for mixing fuel and oil at specified ratios.

Fuel-Oil Mixing Procedure

Step-by-step procedure for mixing engine oil and gasoline.

Auto Mixing System

Auto Mixing System Operation

Explanation of the auto-mixing system and oil tank replenishment.

Engine Oil Tank Refill

Procedure for filling the engine oil tank.

Oil Pump Air Venting

Oil Pump Air Vent Procedure

Procedure to check and purge air from the oil pump.

Engine Break-In

Engine Break-In Procedure

Instructions and table for breaking in the new outboard motor.

Break-In Fuel Mixing Ratios

Specifies fuel mixing ratios for break-in for pre-mixing and auto-mixing types.

Warning System Overview

Warning Horn and Lamp Functions

Explanation of warning indicators for abnormal conditions.

Warning Indicator Locations

Identifies the locations of the warning horn and LED lamp.

Warning Indicators, Faults, and Remedies

Warning Indicator Table

Table detailing warning indicators, common faults, and their remedies.

Fault Remedy Procedures

Specific Fault Remedies

Detailed remedies for specific warning indicators and faults.

ENGINE OPERATION

Pre-Start Checks

Pre-start checks and procedures, including oil and fuel system preparation.

Engine Oil Priming

Procedure for forced feeding engine oil to the oil line before starting.

Fuel System Connection

Fuel Feeding Procedure

Step-by-step procedure for connecting the fuel system and fueling.

Starting Engine Procedure

Starting Engine Instructions

Instructions for starting the engine, including test tank setup and cautions.

Engine Starting Methods

Tiller Handle Starting Method

Steps for starting the engine using the tiller handle.

Side Mount RC Starting Method

Steps for starting the engine using the side mount remote control.

Engine Starting Mechanisms

Manual Starter Operation

Procedure for starting the engine with a manual starter.

Electrical Starter Operation

Procedure for starting the engine with an electrical starter.

Engine Starting Details

Tiller Handle Starting Details

Steps for starting the engine with a tiller handle, including choke use.

Side Mount RC Starting Details

Steps for starting the engine with a side mount RC, including choke use.

Emergency Starting Cautions

Warnings and precautions for emergency engine starting methods.

Manual Starter Operation Details

Manual Starter Steps

Detailed steps for manual starting, including rope handling.

Engine Warm-Up and Operation

Engine Warm-Up Procedure

Instructions for warming up the engine to circulate oil and prevent damage.

Forward, Reverse, and Acceleration

Guidelines for shifting into gear and accelerating safely.

Shifting and Acceleration

Tiller Handle Shifting Operations

Procedures for shifting gears and accelerating with a tiller handle.

Acceleration Safety Precautions

Cautions for smooth acceleration to prevent passenger injury.

Control Lever Operations

Control Lever Forward/Reverse Engagement

Steps for engaging forward and reverse gears using the control lever.

Control Lever Acceleration

Instructions for gradual acceleration using the control lever.

Stopping the Engine

Engine Stopping Procedures

Procedures for safely stopping the engine on tiller and RC models.

Emergency Engine Stop and Steering

Emergency Engine Stop Method

Method for emergency engine stopping using the stop switch lock.

Steering Operation Guide

Instructions for turning the tiller handle or steering wheel.

Trim Angle Adjustment

Trim Angle Importance and Identification

Importance of trim angle and how to identify the proper setting for hull performance.

Trim Angle Adjustments for Bow Position

How to adjust trim when the bow rises too high or dips low.

Tilt and Trim Adjustments

Manual Tilt Trim Adjustment

Steps for adjusting trim angle on manual tilt models.

Power Tilt Trim Adjustment

Steps for adjusting trim angle on power tilt models.

Tilting the Outboard Motor

Tilting Up and Down Procedure

Procedures for tilting the outboard motor up and down.

Manual Tilt Up/Down Procedure

Detailed steps for tilting up and down on manual tilt models.

Power Tilt and Manual Valve

Power Tilt Up/Down Procedure

Steps for tilting up and down on power trim & tilt models.

Manual Relief Valve Usage

How to use the manual relief valve for tilting if power tilt fails.

Shallow Water Operation

Shallow Water Operating Precautions

Precautions and procedures for operating in shallow water.

Manual Tilt Shallow Water Position

Setting the tilt for shallow water running with manual tilt.

Power Tilt Shallow Water Position

Power Tilt Shallow Water Running

Setting the tilt for shallow water running with power tilt.

REMOVING AND CARRYING THE OUTBOARD MOTOR

Removing the Outboard Motor

Step-by-step instructions and warnings for removing the outboard motor from the boat.

Carrying the Outboard Motor

Outboard Motor Carrying Precautions

Warnings and cautions for safely carrying the outboard motor.

Trailering Precautions

Trailering the Boat with Motor

Precautions for trailering the boat with the outboard motor attached.

ADJUSTMENT

Steering Friction Adjustment

How to adjust the steering friction on tiller handle models.

Throttle Grip Friction Adjustment

How to adjust throttle grip friction using the adjustment screw.

Control System Adjustments

Remote Control Lever Friction

How to adjust friction on the remote control lever.

Trim Tab Adjustment Guide

How to adjust the trim tab for straight-line cruising.

INSPECTION AND MAINTENANCE

Importance of Regular Maintenance

Emphasizes regular inspection and maintenance for optimal operation.

Daily Inspection Checklist

Pre-Use System Checks

Checklist of daily checks for various systems before and after use.

Engine Oil and Motor Washing

Engine Oil Replenishment Procedure

Procedure and cautions for replenishing engine oil.

Washing the Outboard Motor

Warnings and cautions for washing the outboard motor.

Cooling System Flushing

Flushing Attachment Use Guide

Instructions for using a flushing attachment to clean the cooling system.

Flushing in Test Tank Procedure

Procedure for flushing the engine using a test tank.

Fuse Replacement

Electrical Fuse Replacement

Steps for replacing fuses in the electrical system.

Periodic Inspection Schedule

Periodic Inspection Actions

Servicing intervals and actions for periodic inspection of the outboard motor.

Fuel System Maintenance

Fuel Filter and Tank Cleaning

Procedures for cleaning fuel filters and the fuel tank.

Engine Fuel Filter Maintenance

Steps for checking and cleaning the engine's fuel filter.

Fuel Filter and Gear Oil

Fuel Tank Filter Maintenance

Steps for removing and cleaning the fuel filter for the fuel tank.

Gear Oil Replacement Procedure

Procedure for draining and refilling gear oil.

Propeller Replacement

Propeller Replacement Guide

Warnings and steps for replacing the propeller.

Spark Plug Replacement

Spark Plug Replacement Procedure

Procedures and cautions for replacing spark plugs.

Spark Plug Installation

Spark Plug Installation Details

Detailed steps for inspecting, gapping, and installing spark plugs.

Spark Plug Torque Specification

Specification for spark plug tightening torque.

Anode Replacement

Anode Replacement Guide

Information on replacing sacrificial anodes to prevent corrosion.

Power Tilt Oil Check

Power Tilt Oil Checking Procedure

Procedure for checking power tilt unit oil level.

Lubrication Points

Grease Point Identification

Diagrams indicating lubrication points requiring waterproof grease.

Off-Season Storage Preparation

Off-Season Storage Guide

Comprehensive guide for preparing the outboard motor for off-season storage.

Storage Preparation Details

Engine Storage Preparation

Steps for preparing the engine for storage, including flushing and draining.

Fuel Stabilizer Addition

Procedure for adding fuel stabilizer to prevent fuel deterioration during storage.

Fuel System Draining and Battery

Fuel System Draining Procedure

Detailed procedure for draining the fuel system, including carburetor.

Battery Handling Precautions

Precautions for handling the battery, especially regarding sparks and placement.

Pre-Season Check and Submerged Motor

Pre-Season Check Procedure

Steps for checking the engine and battery before seasonal use.

Submerged Motor Emergency Steps

Emergency measures to take if the outboard motor becomes submerged.

Environmental Precautions

Cold Weather Precautions

Measures to prevent damage from freezing in cold weather.

Striking Underwater Object Procedure

Procedures to follow after striking an underwater object.

TROUBLESHOOTING

Troubleshooting Chart

Table correlating engine problems with potential causes and remedies.

Troubleshooting Engine Issues

Troubleshooting Chart

Continuation of the troubleshooting chart for engine issues.

TOOL KIT AND SPARE PARTS

Included Servicing Tools

List of tools included for servicing the outboard motor.

Included Spare Parts

List of spare parts provided with the motor.

PROPELLER TABLE

Propeller Selection Guide

Table to help select the correct propeller based on load and RPM.