TOHATSU TLDI 50 User manual

TOHATSU
OUTBOARDS

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.

TOHATSU M40D 0M50D
OWNER REGISTRATION AND INDENTIFICATION
Upon purchasing this product, be sure your dealer fills out the WARRANTY
CARD correctly and mails it to the distributor, completely filled in. This card
identifies you as the legal owner of the product and serves as your warranty
registratmn of the same.
Warranty
This Tohatsu product is fully guaranteed against defective materials and
workmanship for the period from the date of purchase, provided that the
purchase has been registered m accordance wth the above.
The warranty does not extend to faults arising from incorrect installation or
maltreatment and becomes void if the umt is altered, modlfled or repaired by
any other than the company or service center appointed by Tohatsu.
Please note that the warranty covers only your Tohatsu product. It does not
extend to your boat, trailer, associated equipment or other accessories.
Please read this manual carefully, and use the product in accordance with the
instructions set forth herein.
Serial Number
Please record the serial number of the engine (indicated on the lower engine
cover and cylinder block) in the space below This number will come in handy
in the evenr of theft or to quickly help identify the product type.
Serial Number :
To you the Customer
Thank you for selecting a Tohatsu product. You are now the proud owner of an
excellent outboard engine. which will serve you for many years to come.
We would like to point out that carefree usage can only be assured on the
condition that this manual is read through in its enurely and mamtenance. as
described later in this manual, are followed carefully. Should difficulty arise
with the engine, please check the trouble against the troubleshooting list at the
end of this manual, and if it can not be remedied, contact an authorized Tohatsu
service shop or your dealer.
We hope you will get much enjoyment from this product and wish you good
luck wth your boating adventures.
Tohatsu Corporation
1

NOTICE
HEED ALL WARNINGS AND CAUTIONS AS SET FORTH HEREIN.
THEY HAVE BEEN INCLUDED FOR YOUR SAFETY AND MUST BE
READ CAREFULLY. NEGLIGENCE IN OBSERVING SUCH WARNINGS
AND CAUTIONS COULD RESULT IN SEVERE INJURY OR DEATH.
EMERGENCY STOP SWITCH
A safety switch in the steermg Handle or in the Remote Control Box will cut off
the engine when the safety switch line is pulled out. This line connects to the
wrist of the operator, effectively preventing injuries from the propeller if he
falls overboad. We highly recommend use of the safety switch line. since it can
save the life of the operator if bad things come to worse. However, we would
also like to point out the drawbacks of the switch to the operator. Accidental
activation of the swtch (such as the line being pulled in heavy seas), could
cause passengers to lose their balance, fall overboard, and could result in loss of
power in heavey sears. strong currents or high winds. Loss of control while
mooring is another potential hazard
To prevent such hazardous situation, the line is curled and will extend to a full
I,300mm.
WARNING
As the operator/driver of the boat, you are responsible for the safety of those
aboard, other crafts around you and that local boating regulations are followed.
As such you should possess thorough knowledge of correct operation of the
boat, its accessories and the engine. Thus. to learn about correct operation and
maintenance of the engine, please read through this manual carefully.
WARNING
It is very difficult for a person standing or floating in the water to take evasive
action should he see a power boat heading in his direction. even at a slow
speed. Therefore, it is strongly recommended that when your boat is in the
immediate vicinity of people in the water, the engine be shifted to neutral and
shut off.
SERIOUS INJURY IS LIKELY IF CONTACT IS MADE WITH A PERSON
IN THE WATER BY A MOVING BOAT, GEAR HOUSING, PROPELLER,
OR ANY SOLID DEVICE RIGIDLY ATTACHED TO A BOAT OR
GEARHOUSING~
2

It is the operator’s responsibility to perform all safety checks and to ensure that
all lubrication and maintenance instructions are complied with for safe
operation It is also the operator’s responsibihty to return the unit to the local
dealer for periodic inspection.
Correct periodic maintenance and good care of this outboard engine will lessen
the chance for problems and keep overall operating expenses at a minimum.
SERVICING, REPLACEMENT PARTS & LUBRICANT.
Only let an authorized TOHATSU service shop perform servicing or main-
tenance on this product. Be sure to use original Tohatsu parts and Tohatsu
lubricants only.
MAINTENANCE
As the owner of this outboard engine. you should have acquanted yourself with
the correct maintenance of the same. Please comply with all instructmns on
lubrication and mamtenance, and return the engine to the dealer for periodic
inspection at the prescribed intervals.
Troublefree operation cannot be expected unless the engine receive correct
periodic maintenance and is taken good care of. Moreover, if such maintenance
is performed periodically, it is not likely that a costly overhaul would ever be
required.
3

CONTENTS
Page
Specifications ..............................................
.6
Nomenclature .............................................. .a
1. Engine Installation on Boat. ...........................
14
I Installation ................................................ .14
2 Stem Bracket Dimentional Drawing ............................ .16
2. Remote Control Box ................................. ..I 8
I Installing the Remote Control Box ............................. .18
2 Connecting the Remote Control Cable to the Remote Control Box 19
3 Connecting the Remote Control Cable to the Engine ................ 21
4 Connecting Cords and Cables ................................. .25
S Installing the Meters ........................................ .25
6 Installing the Drag Link Assembly ............................. .28
IBattely .................................................. ..2 9
3. Fuel Oil and Engine Oil ................................ .3i
1Non Auto-mixing model M40D . M40DEF ..................... .32
M50DEF
2 Auto-mixing model ......................................... -32
M40DEFO. M40DEFTO. M40DEPO - M40DEPTO
M50DEFO - MSODEFTO . M50DEPO. M50DEPTO
4. Running..
............................................ ...3 6
lBreak-in...................................................3 6
2Starting....................................................3 7
3ManualStart................................................4 5
in case of trouble with the Recoil Starter or the Electric Starter Motor
4Warm.up ............................................... ...4 E
5 Overheat Buzzer ........................................... .49
5. Operation ............................................... .so
1 FonvardlReverse Running ................................... .50
2 Shallow Water Running ..................................... .S2
4

3StoppingtheEngine ....................................... ..5 3
6.Trim Adjustment........................................S 7
7. Mooring with the Engine Tilted up ...................
.61
6. Dismounting the Engine from the Boat ............. .65
9. Adjustments ........................................... -67
I Remote Control Lever Load .................................. .67
M40DEPO. M40DEPTO/M50DEPO. M50DEPTO
2 Trim Tab Adjustment ........................................
67
3 Steering Load Adjustment .................................... .68
4 Throttle Grip Turning Load Adjustment ......................... -68
10. Inspection and Maintenance ........................ .69
I Daily Inspection ............................................ .69
2 Periodic Inspection .. ...................................... .73
3ChangingGearOil ........................................ ..7 5
4 Cleaning the Filters .. ...................................... .76
5 Checking and Refilling Oil in the Power Trim &Tilt Unit ........... .77
ll.WinterStorage.........................................7 9
I Engine
2 Battery
3 Electric Starter Mater
12. Pre-season Check ..................................... 80
13. If the Engine Becomes Submerged in Water ....... .82
14. Precautions in Cold Weather ....................... .B2
15. Troubleshooting ..................................... .a2
16. Accessories .......................... .............. .8S
17. Propeller Selection _, ............................ ... -86
18. Optional Accessories ............................... ..8 7
19. Wiring Diagram .......... _,..... _,.................... .89
5

Max. output, KW(PS)
Full Throttle Speed Range 4OPS 4 500 - 5 500
0 $
0
1)
V

Exhaust System through propeller hub exhaust
Lubrication
Fuel Mixing Ratio
Cooling System
Starting System
Ignition
manual mixing in fuel oil
tank Auto-mixing system
50:l (after completing
break-in)
forced water cooling
recoil hand recoil hand starter and electric
starter starter electric starter
break pointless CD. Ignition
Spark plugs M40D NGK B7H.S.10 or Champion L-82 (1.O mm gap)
M50D NGK BBHS-IO or Champion L-78 (1 .O mm gap)
-
-
- I
-
-
I
- t
I
- I
,
Trim Stages 6 5 6 5
Engine oil genuine TOHATSU Engine Oil “SUPER GOLD”
Tohatsu gear oil (API GL5, SAE#SO or #SOW)
Fuel Tank Capacity
Engine Oil Tank Capacity
22.7 liters (6 U.S. gal.)
- 2 liters (0.528 U.S. gal.)
3ear Reduction Rata 13 : 24

M40D
1. Tilt Handle
2. Upper Mo,or cover
3. Hook Lever
4. Water Check Port
5. Tilt Stopper Lever
6. Water Plug
7. Anti Cavilation Plate
8. Trim Tab
9. Propeller
10. Oil Plug (lower)
11. Water Strainer
12. Oil Plug (upper)
13. Stern Bracket
14, Thrust Rod
15. Clamp screw
18. Thronle Grip
17. Shift Lever
18. Slader Handle
19. Safety Switch
20. Choke knob
21. Reverse locking Lever
22. Anode

M4oDEF/MSODEF
17. Shift Lever.
IS. Starter Handle
19. sdety Switch
20. Choke knob
21, Reverse locking Lever
22 Main Switch
23. Battery Cords
24. Anode

M40DEFO/M50DEFO
1.liltHandle
2. Upper Molar Cover
3, Hook Lever
4. Waler Check Porl
5. ill Slopper Lever
8. Waler Plug
7. Anti Cavilalion Plale
8. Trim Tab
9. Propeller
10. Oil Plug (lower)
11, Water Slrainer
12. Oil Plug (upper)
13. stern Bracke,
14. Thrus, Rod
15. Clamp Screw
IS. Thmnle Grip @
17. Shin Lever
18. Starter Handle
19. sa,ety switch
20. Choke knob

M40DEFTO/M50DEFTO
1, Till Handle
2. Upper Motor Cover
3. Hook Lever
4 Waer Check Port
5. Till Stopper Lever
5. water Plug
7. *rut, Cawtatla” Plate
8. Trim Tab
9. Propeller
10. Oil Plug (lower)
11, Water Strainer
12. 011 Plug (upper)
13. Stern Bracket
14. Thrust Rod
15. Clamp Screw
16 Thronle Grip
17. Shin Lever
18. Starter Handle
19. Safety Switch
20. Choke knob
21. Pilot Lamp
22. Mm Switch
23. Battery Cords
24. Power Trim & Tilt
25. Anode
“, ,,,,,, ,,,i, ,,,,, .,,, 81, ,II\ ,,,

M40DEPO/M50DEPO
1. Tilt Handle
2. Upper Motor Cover
3. Hook Lever
4. Water Check Port
5. Tilt Stopper Lever
6. water Plug
7. Anti Cavitation Plate
8. Trim Tab
9. Propeller
10. Oil Plug (lower)
11. Water Strainer
12. Oil Plug (upper)
13. Stern Bracket
14. Thrust Rod
15. Clamp screw
15. Choke Knob
17. Filler Lid
IS. me, connecter
19. Battery cords
20. ReYerSe Locking Lever
21, Anode

M4ODEPTO/MSODEPTO

1. ENGINE INSTALLATION ON BOAT
I
AA WARNING I
The maximum horsepower rating of the engine is indicated on the
CERTIFICATION PLATE on the engine itself. Be sure that the
maximum engine horsepower rating does not exceed that
recommended for your boat. It is very DANGEROUS to operate a
boat with an overpowered engine.
I
AA WARNING I
Do not operate the engine until it has been securely mounted on the
boat in accordance with the instruction below.
1 Installation
0 Sigle-engine Installation
n Position the outboard engine at the
exact center of the stern, and mount
it using a cushioning pad or plate.
(Fig. 1)
@Twin-engine Installation
W Position thk outboard engines 470-
660mm (I 8.5 - 26.0 in.) apart.
measuredfrom an imagined center
line of each engine, in the exact
centerof thestern.(Fig. 2)
I.I~
w
1
c &
A- A-
(Fig. 1)
470 - 680mm
m3.0 in.)
(Fig.2)
14

@Transom Height
Install the engine with the Anti-cavitation Plate at a level 0 - 30mm (0 -
I. I8 in.) below the bottom of the boat. (Fig. 3)
b/
(Fig. 3)
I A CAUTION I
I
Overheating may occur if the Anti-cavitation Plate is at a level higher than the
bottom of the boat, as a result of air sucking. I
W If the hight difference exceeds 0 - 30mm (0 - I.18 in.) engine power
perfromance is likely to be reduced as a result of mcreased water resistance
to the gear case assembly.
@Attaching the Stem Bracket
After positioning the Stem Bracket, fix it with clamp screws then drill four
holes in the transom board, matching the holes in the Stern Bracket. Secure
the engine with the supplied bolts (Ml2 x 90mm) and nuts Be sure to use
the washers The small diameter washers go with the bolts and the larger
diameter washers go wit the nuts
15

The mounting holes may be drilled beforehand by referring to the
dtmentional drawing.
2 Stern Bracket Dimentional Drawing
manual tilting model M40D - M40DEF - M40DEFO - M40DEPO
M50DEF - M50DEFO - M50DEPO
(12mm x lenglh 93mm)
with the Power Trim and Tilt model M40DEFTO - M40DEPTO
M50DEFTO - M50DEPTO
(12mm x lenglh 90mm)
16

NOTE
We recommend that the bolt head of the upper bolts face inward while the
nut5 are kept on the outside of the boat to prevent mjury to thepnsxngers.
NOTES
1. Apply sealing agent, such 01 silicon sealer, behveen the bolts and the
transom board holes when tightening the bolt.
2. Be sure to fti the engine securely with the bolts.
17