TOHATSU 2 Stroke 40C User guide

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Copyright © 2007 Tohatsu Corporation. All rights reserved. No part
of this manual may be reproduced or transmitted in any form or by
any means without the express written permission of Tohatsu
Corporation.

FOREWORD
To get the maximum amount of pleasure and performance out of an
outboard 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.
v
TOHAT5Ll CORPORATION

CONTENTS Page

1. SPECIFICATIONS

2. MAIN PARTS
1) Model M40C
/
0

2) Model M40CEF
t
-4

3) Model M40CEP
M40CEP

3. INSTALLATION
3-I. Mounting the engine on boat
(1) Setting position ..,......_ above keel line
Distance between engines (Fig. 1I
approximately 580 mm V2.8”1
(2) Transom height Fisl. 1 Twm engine mounting
Fit the engines so that the anti-cavitation
plate is 30 - 50 mm (1.2” - 2”) lower than
bottom of the boat by (30 - 50 mm1 (Fig. 21.
(3) Tighten engines to boat by cramp screw
handle and bolt of engine bracket. Tighten Ant,-cavitation plate
engines to boat to prevent loss. (Fig. 31

(4) Tilt angle
The outboard motor is adjustable its tilt angle depending on stern angle of a boat and loading condition.
Choose appropriate tilt angle of the motor that the anti-cavitation plate is paralel to water face while
running.
aProper tilt angle
When the boat is holi-
zontal while running,
a position of the thrust
rod is proper.
l improper tilt angle
Set the thrust rod
lower.
If a bow of a boat
is rising,having heavy
pitching or unstable
straight running, ret
the thrust rod lower.
Set the thrust rod
UPPer
If a bow of a boat
goes under a wave,
set the thrust rod
upper.

3-2. Installing the remote control device
Erplanarion of rlght hand Remme Conrro, BOX is written

I Shift Remme Cable
Throttle Remore Control Cable

(31 Fitting of holder cap
(1) Throttle side
l Take out the grommet from the advancer arm
side of the lower motor cover.
l Set the grommet on the cable after making a I
hole in grommet. I
l Attach holder cap to cable and lock in PoSi-
tion by nut. Throttle ride cable
(2) Shift side Holder cap
l Take out the grommet from the shift lever
side of the lower motor cover. Shift ride cable
l Set grommet in position.
l Attach holder cap to cable and lock in Posi-
tion by nut.
(4) Fitting of remote control cable to engine
Note: Position the control lever to Neutral with free accel lever is in the throtde’closed’ Position.
l Pass throttle cable through hole provided on the lower motor cover advancer arm side.
l Install the holder cap of end tip of the throttle cable on the ball joint.
l Fix the throttle cable by cable clip using groove of the cable.
. Install the grommet on the motor cover lower.
10

(1) Fitting of Cord Assembly
l Pass the Cord Assembly from
the Remote Control Box
through the Motor Cover
Lower and connect terminals
referring drawing right.
l Fix the Cord Assembly by a
clamp.
11

l Set the terminals of the Lead Wires in the ~~5s~eadwirs
Cable Terminal Holder.
3. Fitting the Drag Link
(attached to EP type)
Drag Link parts have been provided.
Refer to the drawing right for fitting.
The Spacer will be needed depending on kinds
of steering cables.
12

3.5. Mounting the battery
(11 Locate the battery box in a convenient position
away from possible spray damage. Securely
fasten both the box and battery so they do not
shake loose.
] The battery capacity is 70AH at 12V. 1
Note:
(1) Use battery leads having sufficient length.
(2) Make sure that the battery leads are not
trapped between motor and boat when
turning. etc.
(3) If leads are incorrectly connected, the starter
may fail to operate.
(4) Be sure to connect (+) and l-1 leads correctly.
If they are misxonnected. charging system
will be damaged.
(51 Keep battery fully charged at all times.
(21 Connect the positive lead (+I to the positive
terminal (+) of the battery. and then connect
the negative lead (6). When disconnecting the
battery always remove the negative lead (-1
first. After connecting peace a protective cover
on the positive terminal (+I to prevent short
circuits.
13

3-6. Preparing the engine for operation end
precautions Always carry a spare tank (can) since running of fuel at sea may result in a serious accident.
Use only TOHATSU genuine engine oil in the
fuel mixture.
[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
j engineoill. 1
having a 2O:l rmxmg ratm (gasohne and
(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 day’s
operation.
14

. FUEL AND LUBRICANT FOR TOHATSU OUTBOARD MOTORS
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 con-
taining such alcohl(s) is not the responsibility of
TOHATSU, and will not be covered under the lim.
ited warranty.
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

121 Break-in Running
1) Break-in running time 10 hours
16

4. STARTING ENGINE
4-l. To start
111 Prsparation to start
M40ClM40C EF type
(1) Confirm if the shift lever is in Neutral position.
(2) Turn the handle grip until the bar mark on the grip faces the
tri-angle mark on the steering handle.
(3) Pull out the choke knob fully.