TOHATSU M 40D2 User manual

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M 40D 2
M 50D 2
OB No.003-11038-CAF1
OWNER’S
MANUAL

ENOM00001-0
READ THIS MANUAL BEFORE USING THE OUTBOARD MOTOR. FAILURE TO FOLLOW THE
INSTRUCTIONS AND SAFETY PRECAUTIONS IN THIS MANUAL CAN RESULT IN SERIOUS
INJURY OR DEATH. KEEP THIS MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE.
Copyright © 2016 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.

3
YOUR TOHATSU OUTBOARD MOTOR
ENOM00006-A
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. Should a problem arise with the
outboard motor, please follow the troubleshooting procedures listed at the end of this
manual. If the problem persists, contact an authorized TOHATSU service shop or dealer.
Please always keep this manual together with the outboard motor as a reference to every-
one who uses the outboard motor. If the outboard motor is resold, make sure the manual
is passed on to the next owner.
We hope you will enjoy your outboard motor and wish you good luck in your boating
adventures.
TOHATSU CORPORATION
ENOM00003-0
PRE-DELIVERY CHECK
Be sure that the product has been checked by an authorized TOHATSU dealer before you
take delivery.

4
ENOM00005-A
Serial Number
In the space below, please record the outboard motor's serial number (indicated both on
the bottom cowl and on the cylinder block). The serial number will be needed when order-
ing parts, and when making technical or warranty inquiries.
Serial Number:
Serial Number: Date of purchase:
ENOF01900-0
ENOF01901-0

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,” “CAUTION,” and “Note.” Always pay special attention to such information to
ensure safe operation of the outboard motor at all times.
ENOW00001-0
Failure to observe will result in severe personal injury or death, and possibly property dam-
age.
ENOW00002-0
Failure to observe could result in severe personal injury or death, or property damage.
ENOW00003-0
Failure to observe could result in personal injury or property damage.
ENON00001-0
Note
This instruction provides special information to facilitate the use or maintenance of the outboard
motor or to clarify important points.
DANGER
WARNING
CAUTION

1. GENERAL SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3. PARTS NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
4. LABEL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
5. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
1. Mounting the outboard motor on boat . . . . . . . . . . . . . . . . . . . . . . . . . . .23
2. Remote control device installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3. Battery installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6. PRE-OPERATING PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1. Fuel handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2. Fuel filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
3. Engine oil recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
4. Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
5. Warning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7. ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
1. Engine oil feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
2. Fuel feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
3. Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
4. Warming up the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
5. Forward, reverse, and acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
6. Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
7. Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
8. Trim angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
9. Tilt up and down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
10.Shallow water operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8. REMOVING AND CARRYING THE OUTBOARD MOTOR. . . . . . . . . . . . . . 57
1. Removing the outboard motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
2. Carrying the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3. Traillering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
9. ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
1. Steering friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
2. Throttle grip friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3. Remote control lever friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
4. Trim tab adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
10. INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
1. Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
2. Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3. Off-season storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4. Pre-season check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5. Submerged outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
6. Cold weather precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7. Striking underwater object. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
CONTENTS

8. Operation with multiple outboard motors . . . . . . . . . . . . . . . . . . . . . . . . . 80
11. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
12. TOOL KIT AND SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
13. PROPELLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

9
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.PROPELLER TABLE
INDEX
2
14
3
4
5
6
7
8
9
10
11
12
13
14
1

10
1
GENERAL SAFETY INFORMATION
ENOM00009-0
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. To learn about the correct operation and maintenance of the outboard motor,
please read through this manual carefully.
It is very difficult for a person standing or floating in the water to take evasive action should
he or she see a power boat heading in his/her direction, even at a slow speed. Therefore,
when your boat is in the immediate vicinity of people in the water, the outboard motor
should be shifted to neutral and shut off.
ENOW00005-0
SERIOUS INJURY IS LIKELY IF A PERSON IN THE WATER MAKES CONTACT WITH A MOV-
ING BOAT, GEAR HOUSING, PROPELLER, OR ANY SOLID DEVICE RIGIDLY ATTACHED TO
A BOAT OR GEAR HOUSING.
ENOM0008-A
EMERGENCY STOP SWITCH
The Emergency Stop Switch will stall the outboard motor when the stop switch lanyard is
pulled off. This stop switch lanyard has to be attached to the operator of the outboard
motor to minimize or prevent injuries from the propeller in case the operator falls over-
board.
It is operator’s responsibility to use the Emergency Stop Switch Lanyard.
ENOW00004-A
Accidental activation of the Emergency Stop Switch (such as the tether being pulled out in
heavy seas) could cause passengers to lose their balance and even fall overboard, or it
could result in loss of power in heavy seas, strong currents, or high winds. Loss of control
while mooring is another potential hazard.
To minimize accidental activation of the Emergency Stop Switch, the 500 mm (20 inch.) stop
switch lanyard is coiled and can extended to a full 1300 mm (51 inch.).
ENOM00800-A
PERSONAL FLOATATION DEVICE
As the operator/driver and passenger of the boat, you are responsible to wear a PFD (Per-
sonal Floatation Device) while on the boat.
WARNING
WARNING

GENERAL SAFETY INFORMATION 11
1
ENOM00010-0
SERVICING, REPLACEMENT PARTS & LUBRICANTS
We recommend that only an authorized service shop perform service or maintenance on
this outboard motor. Be sure to use genuine parts, genuine lubricants, or recommended
lubricants.
ENOM00011-A
MAINTENANCE
As the owner of this outboard motor, you should be acquainted with correct maintenance
procedures following maintenance section of this manual (See page 62). It is the opera-
tor's responsibility to perform all safety checks and to ensure that all lubrication and main-
tenance instructions are complied with for safe operation. Please comply with all
instructions concerning lubrication and maintenance. You should take the engine to an
authorized dealer or service shop for periodic inspection at the prescribed intervals.
Correct periodic maintenance and proper care of this outboard motor will reduce the
chance of problems and limit overall operating expenses.
Carbon Monoxide Poisoning Hazard
Exhaust gas contains carbon monoxide, a colorless and odorless gas which can be fatal if
inhaled for any length of time.
Never start or operate the engine indoors or in any space which is not well ventilated.
Gasoline
Gasoline and its vapors are very flammable and can be explosive. Use extreme care when
handling gasoline. You should be thoroughly knowledgeable on how to correctly handle
gasoline by reading this manual.

12
2
SPECIFICATIONS
ENOM00810-B
MODEL FEATURE
*1: Option
ENOM00811-B
MODEL NAME EXAMPLE
M50D2 MFL
Model M40D2 M50D2
Type MF EFTO EPO EPTO MF EFTO EPO EPTO
Transom heights
Sz z z z z z
Lzz zzzzz
LL z
UL z z
Tiller Handle z z z z
Remote Control z z z z
Multi-function tiller handle
Power Tilt z z z z
Gas-assisted tilt
Mnual tilt z z z z
M50 D 2 E P T O L
Model description Horse
power
Product
genera-
tion
Minor
change Starter system Steering system Tilt system Lubrication system Shaft length
M(X)= Two stroke
F= Four stroke
D= Two stroke DI -A and
up 2 and up
E= Elec-
trical start
M= Man-
ual start
P=Remotecontrol
(Pleasure)
F=Tiller handle
(Fisher)
*Multi-function
tiller handle is
available as an
optional part
T=Power
trim&tilt
G=Gas
assist
Blank=
Manual tilt
O=Oil auto-
mixing
Blank=Oil
Pre-mixing
S= Short 15 in
L= Long 20 in
LL= super long
23in
UL= Ultra long
25 in

SPECIFICATIONS 13
2
ENOM01650-0
Remark: Specifications subject to change without notice.
Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
40D2 50D2 MF
Item MODEL 40D2 50D2
MF
Overall Length mm (in) 1143 (45.0)
Overall Width mm (in) 384 (15.1)
Overall Height
S mm (in) 1225 (48.2)
L mm (in) 1352 (53.2)
LL mm (in) 1427 (56.2)
UL mm (in) 1479 (58.2)
Transom Height
S mm (in) 403 (15.9)
L mm (in) 530 (20.9)
LL mm (in) 605 (23.8
UL mm (in) 657 (25.9)
Weight
S kg (lb) 72 (159)
L kg (lb) 73.5 (162)
LL kg (lb) 74.0 (163)
UL kg (lb) 75.0 (165)
Output kW (ps) 40D2: 29.4 (40), 50D2: 37 (50)
Max. Operating Range rpm 40D2: 5000-5700, 50D2: 5150-5850
Idle Speed in Neutral Gear rpm 900
Trolling Speed in Forward Gear rpm 750
Engine Type 2-Stroke
Number of Cylinder 3
Bore x Stroke mm (in) 68 x 64 (2.68 x 2.52)
Piston Displacement mL (Cu in) 697 (42.53)
Exhaust System Through hub exhaust
Cooling System Forced water cooling
Lubrication System Engine oil mixed gasoline
Starting System Manual
Ignition System Flywheel Magneto C.D. Ignition
Spark Plugs 40D2 : NGK B7HS-10/BR7HS-10
50D2 : NGK B8HS-10/BR8HS-10
Alternator 12V, 130W (12V, 11A)
Trim Position 6
Fuel Unleaded regular gasoline pump posted 87 Octane (research octane rating of 91)
Fuel Tank Capacity L (US gal) 25 (6.6)
Engine Oil Genuine motor oil or recommended one (TCW-III)
Fuel : Engine Oil mixing Ratio Unleaded Gasorine 50 : Genuine 2-stroke Engine Oil 1
Gear Oil Genuine Gear Oil or API GL5, SAE #80 to #90, approx. 500ml (16.9 fl.oz)
Gear Shift Dog clutch (F-N-R)
Gear Reduction Ratio 1.85 (13 : 24)

SPECIFICATIONS14
2
ENOM01651-0
Remark: Specifications subject to change without notice.
Tohatsu outboard is power rated in accordance with ISO8665 (propeller shaft output).
40D2 50D2 EFTO, EPO, EPTO
Item MODEL 40D2 50D2
EFTO EPO EPTO
Overall Length mm (in) 1143 (45.0) 630 (24.8)
Overall Width mm (in) 384 (15.1) 1212 (47.7) 355 (14.0)
Overall Height S mm (in) 1225 (48.2) 1212 (47.7)
L mm (in) 1352 (53.2) 1339 (52.7)
Transom Height S mm (in) 403 (15.9)
L mm (in) 530 (20.9)
Weight S kg (lb) 87.5 (193) 74.5 (164) 83.5 (184)
L kg (lb) 89 (196) 76 (168) 85 (187)
Output kW (ps) 40D2: 29.4 (40), 50D2: 37 (50)
Max. Operating Range rpm 40D2: 5000-5700, 50D2: 5150-5850
Idle Speed in Neutral Gear rpm 900
Idle Speed in Forward Gear rpm 750
Engine Type 2-Stroke
Number of Cylinder 3
Bore x Stroke mm (in) 68 x 64 (2.68 x 2.52)
Piston Displacement mL (Cu in) 697 (42.53)
Exhaust System Through hub exhaust
Cooling System Forced water cooling
Lubrication System Auto oil mixing
Starting System Electric starter motor
Ignition System Flywheel Magneto C.D. Ignition
Spark Plugs 40D2 : NGK B7HS-10/BR7HS-10
50D2 : NGK B8HS-10/BR8HS-10
Alternator 12V, 130W (12V, 11A)
Trim Position 4 64
Fuel Unleaded regular gasoline pump posted 87 Octane (research octane rating of 91)
Fuel Tank Capacity L (US gal) 25 (6.6)
Engine Oil Genuine motor oil or recommended one (TCW-III)
Fuel : Engine Oil mixing Ratio Unleaded Gasorine 120-50 : Genuine 2-stroke Engine Oil 1
Gear Oil Genuine Gear Oil or API GL5, SAE #80 to #90, approx. 500mL
Gear Shift Dog clutch (F-N-R)
Gear Reduction Ratio 1.85 (13 : 24)

15
3
PARTS NAME
ENOM01653-0
1Tilt Handle
2Top Cowl
3Hook Lever
4Water Check Port
5Reverse Lock Lever
6Water Plug
7Anti-ventilation Plate
8Trim Tab
9Propeller
10 Oil Plug (lower)
11 Water Strainer
12 Oil Plug (upper)
13 Clamp Bracket
14 Thrust Rod
15 Clamp Screw
16 Throttle Grip
17 Adjust Nut
18 Shift Lever
19 Starter Handle
20 Stop Switch
21 Choke Knob
22 Anode
23 Fuel Filter
24 Spark Plug
40D2MF/50D2MF
1
2
3
4
5
6
7
8
9
18
17
12
11
10
19 20
21
5
15
14
13
22
16
23 24
ENOF1902-0

PARTS NAME16
3
ENOM01656-0
1Tilt Handle
2Top Cowl
3PTT Switch
4Hook Lever
5Water Check Port
6Tilt Stopper
7Water Plug
8Anti-ventilation Plate
9Trim Tab
10 Propeller
11 Oil Plug (lower)
12 Water Strainer
13 Oil Plug (upper)
14 Clamp Bracket
15 Thrust Rod
16 Clamp Screw
17 Throttle Grip
18 Adjust Nut
19 Shift Lever
20 Starter Handle
21 Stop Switch
22 Choke Knob
23 Pilot Lamp
24 Main Switch
25 Battery Cords
26 Power Trim & Tilt
27 Anode
28 Oil Tank
29 Fuel Filter
30 Spark Plug
31 Oil Filter
40D2EFTO/50D2EFTO
1
2
4
5
6
7
8
9
10
19
18
13
12
11
20
21
22
16
15
14
17
23
25
24
26 27
28 30
29
31
3
ENOF01952-0

PARTS NAME 17
3
ENOM01657-0
1Tilt Handle
2Top Cowl
3Hook Lever
4Water Check Port
5Reverse Lock Lever
6Water Plug
7Anti-ventilation Plate
8Trim Tab
9Propeller
10 Oil Plug (lower)
11 Water Strainer
12 Oil Plug (upper)
13 Clamp Bracket
14 Thrust Rod
15 Clamp Screw
16 Choke Knob
17 Filler Lid
18 Fuel Connecter
19 Battery Cords
20 Anode
21 Oil Tank
22 Fuel Filter
23 Spark Plug
24 Oil Filter
40D2EPO/50D2EPO
1
2
3
4
5
6
7
8
9
19
12
11
10
15
14
13
20
16
17
18
21 23
22
24
ENOF01953-0

PARTS NAME18
3
ENOM01658-0
1Tilt Handle
2Top Cowl
3PTT Switch
4Hook Lever
5Water Check Port
6Tilt Stopper
7Water Plug
8Anti-ventilation Plate
9Trim Tab
10 Propeller
11 Oil Plug (lower)
12 Water Strainer
13 Oil Plug (upper)
14 Clamp Bracket
15 Thrust Rod
16 Choke Knob
17 Filler Lid
18 Fuel Connecter
19 Battery Cords
20 Power Trim & Tilt
21 Anode
22 Oil Tank
23 Fuel Filter
24 Spark Plug
25 Oil Filter
40D2EPTO/50D2EPTO
1
2
4
5
6
7
8
9
10
19
13
12
11
15
14
16
17
18
21
22 24
23
25
3
20
ENOF01954-0