Tohatsu - MFS25B Owner's Manual 2009

OWNER’S
MANUAL
OWNER’S MANUAL
MFS 25B
MFS 25B TOHATSU CORPORATION
30B
30B
Address : 5-4, 3-chome, Azusawa, Itabashi-ku,
TOKYO, 174-0051 JAPAN
Phone : TOKYO (03)3966-3117
FAX : TOKYO (03)3966-2951 OB No.003-11080-4
URL : www.tohatsu.co.jp
003-11080-4 1012NB
Printed in Japan
TOHATSU_25B_30B_E_cover.indd 1 11/02/15 11:41

! 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 © 2009 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.

YOUR TOHATSU OUTBOARD MOTOR
OWNER REGISTRATION AND IDENTIFICATION
Upon purchasing this product, be sure that the WARRANTY CARD is correctly and
completely filled out and mailed to the addressee noted there on. This WARRANTY
CARD identifies you as the legal owner of the product and serves as your warranty
registration.
TO THE EXTENT PERMITTED BY APPLICABLE LAW, YOUR OUTBOARD MOTOR
WILL NOT BE COVERED BY THE APPLICABLE LIMITED WARRANTY, IF THIS
PROCEDURE IS NOT FOLLOWED.
PRE-DELIVERY CHECK
Be sure that the product has been checked by an authorized TOHATSU dealer
before you take delivery.
Limited Warranty
Please refer to the TOHATSU outboard motor Limited warranty provided to you with
this product, the terms and conditions of which, as amended from time to time, are
incorporated by reference into the manual.
TOHATSU_25B-30B_E.indd 1 11/02/15 11:40

Serial Number
In the space below, please record the outboard motor's serial number (indicated
both on the lower motor cover and on the cylinder block). The serial number will be
needed in the event of theft or to quickly identifying the outboard motor type.
Serial Number :
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.
We hope you will enjoy your outboard motor and wish you good luck in your
boating adventures.
TOHATSU CORPORATION
TOHATSU_25B-30B_E.indd 2 11/02/15 11:40

CONTENTS
■ GENERAL SAFETY INFORMATION・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 8
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1 SPECIFICATIONS ・
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2 NAMES OF PARTS ・・・
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3 INSTALLATION・・
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1. Mounting the outboard motor on boat ・・・・・・
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2. Installing the remote control devices ・
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3. Installing the battery ・・
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4 PRE-OPERATING PREPARATIONS・・・・・
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1.Gasoline and engine oil ・・・
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2.Break-in ・・・・・
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3.Warning system・・
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5 ENGINE OPERATION・・・・・
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Before starting ・・・・・
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1.Starting ・・・・・・
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2.Warming up the engine ・・・
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3.Forward and reverse ・・
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4.Stopping ・・・・
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5.Trim angle ・・・
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6.Tilt up, tilt down and shallow water operation ・
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6 REMOVING AND CARRYING THE OUTBOARD MOTOR ・・
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1.Removing the outboard motor・・・・・・・・・
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2.Carrying the outboard motor・・・
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3.Storing the outboard motor ・・・・
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7 TRAILERING ・・・
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8 ADJUSTMENT・・
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1.Steering friction ・・
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2.Throttle grip ・・・・・・
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3.Remote Control Lever Load ・・・
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4.Trim Tab Adjustment ・・・
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9 INSPECTION AND MAINTENANCE・・・・・
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1.Daily inspection ・・
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2.Periodic inspection ・・・・
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3.Off-season storage ・・・・
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4.Pre-season check ・・・・・
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5.Motor submerged in water ・・・・
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6.Cold weather precautions ・・・・・
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7.Checking after striking underwater object ・・
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10 TROUBLESHOOTING ・・・・
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11 TOOL KIT AND SPARE PARTS・・
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12 OPTIONAL ACCESSORIES・・
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13 PROPELLER TABLE・・・・・・
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TOHATSU_25B-30B_E.indd 4 11/02/15 11:40
7
INDEX
GENERAL SAFETY INFORMATION

1. SPECIFICATIONS 1
2. NAMES OF PARTS 2
3. INSTALLATION 3
4.PRE-OPERATING PREPARATIONS 4
5.ENGINE OPERATION 5
6.REMOVING AND CARRYING THE MOTOR 6
7.TRAILERING 7
8.ADJUSTMENT 8
9.INSPECTION AND MAINTENANCE 9
10.TROUBLESHOOTING 10
11.TOOL KIT AND SPARE PARTS 11
12.OPTIONAL ACCESSORIES 12
13.PROPELLER TABLE 13
TOHATSU_25B-30B_E.indd 7 11/02/15 11:40

GENERAL SAFETY INFORMATION
NOTICE : DANGER/WARNING/CAUTION/Note
Before installing, operating or otherwise handling your outboard motor, be sure
to thoroughly read and understand this Owner's Manual and carefully follow all of
the instructions. 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.
! DANGER
Failure to observe will result in severe personal injury or death, and possibly property damage.
! WARNING
Failure to observe could result in severe personal injury or death, or property damage.
! CAUTION
Failure to observe could result in personal injury or property damage.
Note
This instruction provides special information to facilitate the use or maintenance of the
outboard motor or to clarify important points.
EMERGENCY STOP SWITCH

The Emergency Stop Switch will stall the outboard motor when the stop switch
tether is pulled off. This stop switch tether can be attached to the operator of
the outboard motor to minimize or prevent injuries from the propeller in case the
operator falls overboard.
We highly recommend use of the Emergency Stop Switch tether.
! WARNING
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 tether is coiled and can extended to a full 1,300 mm (51 inch.).
TOHATSU_25B-30B_E.indd 8 11/02/15 11:40

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.
! WARNING
SERIOUS INJURY IS LIKELY IF A PERSON IN THE WATER MAKES CONTACT WITH
A MOVING BOAT, GEAR HOUSING, PROPELLER, OR ANY SOLID DEVICE RIGIDLY
ATTACHED TO A BOAT OR GEAR HOUSING.
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.
MAINTENANCE
As the owner of this outboard motor, you should be acquainted with correct
maintenance procedures. 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. 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.
MOUNTING
Outboard motor mounting must be performed by trained service person(s) using
lift or hoist with sufficient capacity.
TOHATSU_25B-30B_E.indd 9 11/02/15 11:40

10
SPECIFICATIONS
MF , EF , EP
MODEL 25B MF 25B EF 25B EP
1 Item 30B MF 30B EF 30B EP

Overall Length mm (in) 1,031 (40.6) 652 (25.7)
Overall Width mm (in) 391 (15.4) 367 (14.4)

2 Overall Height S·L mm (in) 1,187 (46.7) · 1,335 (52.6)
Transom Height S·L mm (in) 404 (15.9) · 552 (21.7)

3 S Kg (lb) 71.5 (158) 74.5 (164) 73 (161)
Weight
L Kg (lb) 73 (161) 76 (167) 74.5 (164)
4 Output kW (Hp) 25B : 18.4 (25) 30B : 22.1 (30)
25B : 5,000-6,000
Max. Operating Range rpm
30B : 5,250-6,250
5 Idle Speed rpm 850 + or - 30
Engine Type 4-Stroke EFI

6 Number of Cylinder 3
Bore × Stroke mm (in) 61 × 60 (2.40 × 2.36)
7 Piston Displacement mL (Cu in) 526 (32.09)
Exhaust System Through hub exhaust
8 Cooling System Water cooling
Engine Lubrication Trochoid pump
9
Startring System Manual Electric starter motor*
Ignition System Flywheel Magneto C.D. ignition
Spark Plug NGK DCPR6E

10 Trim Position 6
NMMA FC-W certified 10W-30 or

11 Engine Oil mL (qt.) API SF, SG, SH, SJ, SL or SM, 10W-30/40
Approx. 1,800 (1.9)
Genuine Gear Oil or API GL5,

Gear Oil mL (fl.oz.)
12 SAE #80-90, Approx. 280 (9.5)
Fuel Tank Capacity L (US gal) 25 (6.60)
13
Gear Reduction Ratio 1.92 (12 : 23)
Emission Control System ECU
＊ : with manual ※ Specifications subject to change without notice.

14
TOHATSU_25B-30B_E.indd 10 11/02/15 11:40

SPECIFICATIONS 11
MFG , EFG
MODEL 25B MFG 25B EFG

Item 30B MFG 30B EFG
1
Overall Length mm (in) 1,031 (40.6)
Overall Width mm (in) 391 (15.4)
Overall Height S·L mm (in) 1,187 (46.7) · 1,335 (52.6)

2
S Kg (lb) 78 (172) 81 (179) 3

Weight
L Kg (lb) 79.5 (175) 82.5 (182)
Output 25B : 18.4 (25) 30B : 22.1 (30) 4

25B : 5,000-6,000
30B : 5,250-6,250
Idle Speed rpm 850 + or - 30

5
Number of Cylinder 3 6
Bore × Stroke mm (in) 61 × 60 (2.40 × 2.36)
Piston Displacement mL (Cu in) 526 (32.09) 7

Cooling System Water cooling

8
Startring System Manual Electric starter motor*

9
Trim Position 4
10
Engine Oil mL (qt.) API SF, SG, SH, SJ, SL or SM, 10W-30/40
Approx. 1,800 (1.9)
11
SAE #80-90, Approx. 280 (9.5)
12

13
TOHATSU_25B-30B_E.indd 11 11/02/15 11:40

12 SPECIFICATIONS
EFT , EPT
MODEL 25B EFT 25B EPT
1
Item 30B EFT 30B EPT
Overall Length mm (in) 1,031 (40.6) 652 (25.7)
Overall Width mm (in) 391 (15.4) 367 (14.4)

2 Overall Height S·L mm (in) 1,187 (46.7) · 1,335 (52.6)
3 S Kg (lb) 82.5 (182) 81 (179)

Weight
L Kg (lb) 84 (185) 82.5 (182)
4 Output 25B : 18.4 (25) 30B : 22.1 (30)
25B : 5,000-6,000
30B : 5,250-6,250
5 Idle Speed rpm 850 + or - 30

6 Number of Cylinder 3
Bore × Stroke mm (in) 61 × 60 (2.40 × 2.36)
7 Piston Displacement mL (Cu in) 526 (32.09)
8 Cooling System Water cooling
9
Startring System Electric starter motor*

10 Trim Position 4
11 Engine Oil mL (qt.) API SF, SG, SH, SJ, SL or SM, 10W-30/40
Approx. 1,800 (1.9)

12 SAE #80-90, Approx. 280 (9.5)
13

14
TOHATSU_25B-30B_E.indd 12 11/02/15 11:40

13
NAMES OF PARTS
MF , EF , EP
○
1
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19 ○
20
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21
1
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18
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22
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2
2 17
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3
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4
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23
3
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16
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4
5
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15
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14
5
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6
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13
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7
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8
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12
6
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11
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9
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10
7
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25
EP type only
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8
30
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24
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26 ○
31
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27
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32
＊：MF and EF type only.

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33
9
☆：EF type only. ○
28
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29
① Tilt Handle ○
12 Oil Plug (Upper) ○
23 Fuel Connector 10
② Top Cowl ○
13 Drive Shaft Housing ○
24 Primer Bulb
③ Bottom Cowl ○
14 Thrust Rod ○
25 Fuel Connector
④ Cooling Water Check Port ○

15 Clamp Bracket ○
26 Fuel Tank Cap 11
⑤ Oil Drain Bolt ○
16 Clamp Screw ○
27 Air Vent Screw
⑥ Anti Ventilation Plate 17 ＊ Throttle Grip

○ ○
28 Fuel Pick up Elbow
⑦ Trim Tab 18 ＊ Shift Lever

○ ○
29 Fuel Tank 12
⑧ Sub Water Inlet ○
19 Starter Handle ○
30 Remote Control
⑨ Water Inlet ○
20 Stop Switch ○
31 Main Switch
⑩ Propeller ○
21 Warning Lamp ○
32 Stop Switch 13
○
11 Oil Plug (Lower) 22 ☆ Starter Switch
○ ○
33 Cord Assembly
TOHATSU_25B-30B_E.indd 13 11/02/15 11:40

14 NAME OF PARTS
MFG , EFG
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1
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21
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20
1 ○
19
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22
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2
2
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18
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23
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3
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3
24
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4
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17
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4 ○
16 25
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5
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15
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14
5 ○
6
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13
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7
6 ○
12
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8 ○
11
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9
7 ○
10
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27
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26
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28
8 ○
29
9 ○
31
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30
① Tilt Handle ○
11 Oil Plug (Lower) ○
21 Stop Switch
10 ② Top Cowl ○
22 Warning Lamp
③ Bottom Cowl ○
23 Starter Switch (EFG type only)
④ Cooling Water Check Port ○

14 Thrust Rod ○
24 Fuel Connector
11 ⑤ Oil Drain Bolt ○

25 Shock Absorber
⑥ Anti Ventilation Plate ○

16 Lock Lever ○
26 Primer Bulb
⑦ Trim Tab ○
17 Tilt Stopper ○
27 Fuel Connector
12 ⑧ Sub Water Inlet ○

18 Throttle Grip ○
28 Fuel Tank Cap
⑨ Water Inlet ○
19 Shift Lever ○
29 Air Vent Screw
⑩ Propeller ○
30 Fuel Pick up Elbow
13 ○
31 Fuel Tank
14
TOHATSU_25B-30B_E.indd 14 11/02/15 11:40

NAME OF PARTS 15
EFT , EPT
○
1 ○
21 ○
22
○
20 ○
23
1
○
24
○
2 ○
2
19
○
3
○
3
25
○
4
○
18
○
5
○
17
○
26
○
6 ○
16 4
○
7 ○
15
○
14 5
○
8
○
9
○
13
6
○
12
○
10
○
11 7
○
28
EPT type only
○
33 ○
34
○ ○
8
27 35
○
29
○
30
○
36
＊：EFT type only. ○

32
○
31 ○
38
○
37
9
① Tilt Handle ○
27 Primer Bulb
② Top Cowl ○
15 Thrust Rod ○
28 Fuel Connector 10
③ Bottom Cowl ○
29 Fuel Tank Cap
④ Power Tilt Switch ○

17 Tilt Stopper ○
30 Air Vent Screw
⑤ Cooling Water Check Port 18 ＊ Clamp Screw

○ ○
31 Fuel Pick up Elbow 11
⑥ Oil Drain Bolt 19 ＊ Throttle Grip
○ ○
32 Fuel Tank
⑦ Anti Ventilation Plate 20 ＊ Shift Lever

○ ○
33 Power Tilt Switch
⑧ Trim Tab ○
34 Remote Control
12
⑨ Sub Water Inlet ○
22 Stop Switch ○
35 Main Switch
⑩ Water Inlet ○
23 Warning Lamp ○
36 Stop Switch
○
11 Propeller
○
12 Oil Plug (Lower)
24 ＊ Starter Switch
○
○
25 Fuel Connector
○
37 Cord Assembly
○
38 Emergency Stop
13
○
26 Power Tilt Switch Tether
TOHATSU_25B-30B_E.indd 15 11/02/15 11:40

16
INSTALLATION
1. Mounting the outboard motor on boat MF, EF, EP type
① To attach the outboard motor to the
boat, tighten the clamp screws by
! WARNING
1 Most boats are rated and certified
turning their handles.
Also, use the bolts to secure
in terms of their maximum allowable the outboard motor brackets on
2
horsepower, as shown on the boat’ transom board.
s certification plate. Do not equip
Secure the outboard motor with a
your boat with an outboard motor that
exceeds this limit. If in doubt, contact rope to prevent loss overboard.
3 your dealer.
Note
Do not operate the outboard motor
until it has been securely mounted
A rope is not included in the standard
4 on the boat in accordance with the
instructions below. accessories.
Position ... Above keel line

5 Set engine at center of boat.
Nut
Center of Boat
Bolt (8×85)
6 Washer
Clamp screw
7 Boat Transom ! CAUTION

● Before beginning the running test,
8 check that the boat with maximum
capacity loading floats on the
Transom matching water in a proper attitude. Check
9 Be sure that the anti ventilation plate

of the outboard motor is 5-25mm
the position of water surface on
the driveshaft housing. If the water
surface is near the bottom cowling,
(0.2-1 in) below the bottom of hull.
in high waves, water may enter the
10 If the above condition cannot be met
due to the shape of the bottom of your
engine cylinders.
● Incorrect outboard motor mounting
boat, please consult your authorized height or existence of underwater
11 dealer. object(s), such as hull bottom
design, bottom surface conditions
or underwater accessories, can
cause water spray possibly reaching
12 Bottom of hull the engine through an opening of
5-25mm the bottom cowling during cruising.
(0.2-1”)
Exposing the engine to such
13 Anti Ventilation Plate conditions for extended periods can
lead to severe engine damage.
14
TOHATSU_25B-30B_E.indd 16 11/02/15 11:40

INSTALLATION 17
MFG, EFG, EFT, EPT type

② Power Tilt and Gas Assist type ! CAUTION
Mounting bolts should be installed with
the bolt head at inside surface of the
transom. Mounting bolts installed with
1
Clamp Screw the threaded end at the inside surface of
the transom can cause personal injury.
2
(without EPT type)
A
Notes
Nut
1. Apply sealing agent, such as
3
silicone sealed between the bolts
Bolt
(12×105) Washer
and the transom board holes before
tightening the bolts. 4
(large diameter)
2. Be sure to tighten the mounting bolt
Washer
nuts to the specified torque.
(small diameter)
(30 Nm (3.0kgf)13ft · lb) 5
（327）
163.5 163.5 ! WARNING 6

● Mounting the outboard motor without
7
following this manual can lead to unsafe
conditions such as poor maneuverability,
51
lack of control or fire.

18 18 18
● Loose clamp screws and/or mounting

12.5 bolts can lead to the release or 8
displacement of the outboard motor,
253.5
possibly resulting in lost of control and/or

serious personal injury. Be sure that
fasteners are tightened to the specified 9
torque (30 Nm (3.0kgf)13ft·lb). Check the
fasteners for tightness from time to time.
56
12.5
● Be sure to use outboard mounting 10
fasteners included in the outboard
125.5 125.5
motor package or their equivalents
（251）
View A
in terms of size, material, quality and
strength.
11
Tighten fasteners to the specified
torque (30 Nm (3.0kgf)13ft·lb). Test
cruise to check if fasteners are 12
tightened securely.
● Outboard motor mounting must be
performed by trained service person(s)
using lift or hoist with sufficient capacity.
13
TOHATSU_25B-30B_E.indd 17 11/02/15 11:40

18 INSTALLATION
2. Installing the remote control devices Lock nut

Remoto control cable Cable joint
! WARNING
1 When using other than Tohatsu's genuine
remote control box, DO NOT select the
2
one without neutral safety switch that
Approx. 10mm
prevents in-gear start.
(0.39 inch)
Use of remote control box without neutral
safety switch can allow start of engine with
3 gear at other than neutral shift, potentially ② Fitting of Remote Control Cable to
leading passengers to falling or causing Engine
passenger to be thrown overboard.
4 Note
It is recommended that you consult
with your authorized dealer for Put the control lever in the Neutral
5 installation and adjustment of the position and the Free Accel lever in
the fully closed position.
remote control device.
6 ■ Installation of the Remote Control

Cables (Box side) :
7 Follow the instruction manual S

provided with the remote control. T
8 ■ Installation of the Remote Control S
on your boat : T
Follow the instruction manual

9 provided with the remote control. S
T
10 ■ Installation of the Remote Control

Cable (engine side) and the Cord
T Shift Cable
Throttle Cable
S Cable Harness B
Assembly (Wiring Harness) :
11
① Fitting of connecting parts to cables
12 Screw the tip of the remote control ! CAUTION

cable into the cable joint up to
Be careful not to loop the remote
approx. 10 mm (0.39 inch), then lock
13
control cables to a diameter of 406 mm
them with a lock nut. Apply grease to (16 inches) or less.
the hole of the cable joint.
14
TOHATSU_25B-30B_E.indd 18 11/02/15 11:40

INSTALLATION 19
Note 3. Installing the battery

Confirm the outboard motor shifts
correctly when the shift lever is
① Place the battery box in a convenient
placed in Forward and Reverse
position. also confirm the throttle
position away from possible water
spray. Securely fasten both the box
1
valve is closed at idle, in Neutral, and the battery so they do not shake
Forward, and Reverse. Confirm the
throttle valve is fully open when in
loose. 2
Forward at the wide open position.
Note
Minimum recommended battery : 12V, 3
③ Connecting the Cord assembly 70AH (465 Marine Cranking Amps
(Wiring Harness) (MCA) or 350 Cold Cranking Amps
(CCA)) Specifications and features of 4
Connect cable harness B to cable batteries vary among the manufacturers.
Consult the manufacturer for details.
harness A.
Location of the connectors is near the 5
recoil starter of starboard side in the ! WARNING
cowl.
Battery electrolyte contains sulfuric acid
and thus is hazardous, causing a burn
6
Cable Harness B
(From remote control) if it comes in contact with your skin, or
7
poisonous if swallowed.
Cable Harness A Keep battery and electrolyte away from
(Outboard motor side)
reach of children
When handling the battery, be sure to:
● Read all warnings shown on the 8
battery case
● Prevent electrolyte from coming in
contact with any part of your body.
Contact can cause serious burn or, 9
! WARNING if it comes in contact with your eye,
loss of sight. Use safety glasses and
Do not disconnect the cord assembly rubber gloves. 10
when the outboard motor is in In case battery electrolyte comes in
operation or you will lose control of the contact with:
outboard motor. ● Skin, flush thoroughly with water.
● Eye, flush thoroughly with water,
11
and then seek immediate medical
treatment.
In case battery electrolyte is swallowed: 12
● Seek immediate medical treatment.
13
TOHATSU_25B-30B_E.indd 19 11/02/15 11:40

20 INSTALLATION
! WARNING ② Connect the positive lead (+) to the

Battery generates explosive hydrogen positive terminal (+) of the battery,
1 gas. Be sure to:

● Charge the battery in a well-ventilated
and then connect the negative
lead (−). When disconnecting
place. the battery always remove the
● Place the battery away from any
2 source of fire, sparks and open
negative lead (−) first. After
connecting the positive terminal
flames such as burners or welding
equipment. (+), securely place a cap on it to
3 ● Do not smoke when handling the
battery.
prevent short circuits.
● Do not smoke near the battery when

the battery is charging.
4
5 ! CAUTION
● Make sure that the battery leads do Battery cord
not get stuck between the outboard
6
(black)
motor and boat when turning, etc. Battery cord
(red)
● The starter motor may fail to
operate if the leads are incorrectly
7 connected.
● Be sure to correctly connect the (+)
and (−) leads. If not, the charging
8
system will be damaged.
● Do not disconnect the battery leads
from battery while the engine is
operating, the electrical parts could
9 be damaged.
● Always use a fully charged battery.
10
! CAUTION
11 Do not use a battery that is not
recommended. Use of a battery
not recommended can lead to poor
performance of, and/or damage to, the
12 electrical system.
13
14
TOHATSU_25B-30B_E.indd 20 11/02/15 11:40

21
PRE-OPERATING PREPARATIONS
! DANGER Use of unleaded gasoline
Consult an authorized dealer for details on
handling gasoline, if necessary.
UNITED STATES AND CANADA:
Gasoline and its vapors are very flammable

Use a major brand of automotive unleaded
gasoline with a minimum posted octane
1
and can be explosive. rating of 87. Mid-grade automotive gasoline
When carrying a fuel tank containing gasoline:

that contain fuel injector cleaner are preferred 2
for added internal engine cleanliness. Leaded
● Close the air vent screw of fuel tank cap, or
gasoline vapor will be emitted through the gasoline is not recommended.
air vent screw, creating a fire hazard. INTERNATIONAL : Use a major brand 3
● Do not smoke. of automotive unleaded gasoline with a
minimum posted octane rating of 91RON.
When or before refueling:
● Stop the engine, and do not start the
Automotive gasoline that contain fuel injector 4
engine during refueling. cleaner are preferred for added internal
● Do not smoke. engine cleanliness. Leaded gasoline is
● Be careful not to overfill fuel tank. Wipe up acceptable in areas where unleaded gasoline 5
any spilled gasoline immediately. is not available.
When or before cleaning the gasoline
tank: Use of alcohol free gasoline 6
● Dismount fuel tank from the boat.
● Place the fuel tank away from every source
of ignition, such as sparks or open flames.
! CAUTION 7
● Do the work outdoors or in a well ventilated Use of gasoline containing alcohol can cause
area. engine starting and/or operating difficulties,
● Wipe off gasoline well immediately if spilt. wear of and damages to engine parts, and
deterioration of chemical parts, which may
8
After cleaning gasoline tank: lead to shortening of your outboard motor’s
● Wipe off gasoline well immediately if spilt.
9
life.
● If the fuel tank is disassembled for cleaning,
reassemble carefully. Imperfect assembly
may cause a fuel leak, possibly leading to
Note
fire or explosion.
● Dispose aged or contaminated gasoline in
10
The adverse effect caused by the alcohol content
accordance with local regulations. is more severe with methanol than with ethanol.
11
1. Recommended gasoline types TOHATSU recommend the use of gasoline
if its ethanol content is less than 10% or
! CAUTION methanol content is less than 5%, only in 12
case alcohol free gasoline is not available.
Use of low-quality gasoline results in a short
The alcohol component of the gasoline
engine life as well as starting difficulties and
other engine problems. absorbs moisture from the air, which may 13
We recommend use for Fuel stabilizer. disturb regular fuel flow in the fuel system,
TOHATSU_25B-30B_E.indd 21 11/02/15 11:40

22 PRE-OPERATING PREPARATIONS
and also accelerate rusting of engine parts. life.

Mixing of the moisture in the engine oil Use NMMA FC-W certified 4-stroke engine
can also deteriorate the properties of the oil below.
1 lubricant.
10W-30: is recommended for use in all
If the use of gasoline containing alcohol temperature.
2 is inevitable, or presence of alcohol is 25W-40: may be used at temperatures
suspected in the gasoline, it is strongly above 4˚C (40˚F).
recommended to add a filter that has water You can also use oils that carry the API rating
3 separating capability, and check the fuel of SF, SG, SH, SJ, SL, or SM. Select the
system for leaks and mechanical parts appropriate viscosity, based on atmospheric
for corrosion and abnormal wear more temperature, from the chart below.
4 frequently.
And, in case any of such abnormality is 20W−40, 20W−50
5 found, discontinue the use of such gasoline

and contact our dealer immediately. ENGINE 15W−40, 15W−50
OIL
Damages resulting from the use of gasolines 10W−40, 10W−50
6 that contain alcohol are not covered under
the limited warranty. 10W−30
Fuel tank capacity :
-30 -20 -10 0 10 20 30 40 ˚C
7 25 liters (6.6 U.S. gal)---for 30, 40, 50 -22 -4 14 32 50 68 86 96 ˚F
Fuel Tank : W hen using a fixed fuel Atmospheric temp.
tank in place of genuine fuel tank, it is
8 recommended to select a one with a
structure facilitating interior cleaning. ! CAUTION
9
The engine oil is drained for shipping
! WARNING from the factory. Be sure to fill the
engine to the proper level before
Do not fill the fuel tank over capacity. The
starting engine. (To properly fill the
10 rise of gasoline temperature may cause
gasoline to expand which, if overfilled,
engine with oil follow the instructions in
section 9 of this manual)
may leak through air vent screw when it
is open. Leaking gasoline is a dangerous
11 fire hazard.
Note
12 2. Recommended engine oil

Use of engine oils that do not meet
these requirements will result in
reduced engine life, and other engine
problems.
13 Use only high quality 4-stroke engine oil to
insure performance and prolonged engine
14
TOHATSU_25B-30B_E.indd 22 11/02/15 11:40

PRE-OPERATING PREPARATIONS 23
3. Break-In
Your new outboard motor and lower

unit require break-in for the moving ! CAUTION 1
components according to the Operating the outboard motor without
conditions described in the following break-in can shorten service life of the
time table. product.
If any abnormality is experienced
2
during the break-in:
● Discontinue the operation
immediately. 3
● Have the dealer check the product
and take proper action(s) if
necessary.
4
1-10min 10min-2hrs 2-3hrs 3-10hrs After 10hrs
5
Less than 1/2 Less than 3/4 Full throttle
Throttle Position Idle 3/4 throttle
throttle throttle available
6
Approx.
Speed
Approx.
Full throttle run 4,000 rpm.
allowed for 1 min Full throttle run 7
3,000 rpm max
every 10 min allowed for 2 min
every 10 min
8
Note ! DANGER
Proper break-in allows outboard Do not operate the outboard motor 9
motor to deliver it full performance for in closed area or area with no forced
longer service life. ventilation.
Exhaust gas emitted by this outboard
motor contains carbon monoxide that
10
will cause death if inhaled continuously.
11
Inhaling the gas initially causes
symptoms such as feeling of sickness,
drowsiness and headache.
During operation of the outboard motor:
● Keep peripheral area well ventilated. 12
● Always attempt to stay on the
windward side of emission.
13
TOHATSU_25B-30B_E.indd 23 11/02/15 11:40

24 PRE-OPERATING PREPARATIONS
4. Warning system
Location of warning horn and lamp
If outboard motor encounters an
■ Warning horn
1 abnor mal condition of fault, the
warning horn will emit a continuous Located inside the remote control
beep or intermittent short beeps for EP models. Located in the top
2 and the warning lamp (LED) will
synchronize with the horn and engine
cowl for other models.
■ Warning lamp (LED)
speed will be limited (engine will not Located on the front of bottom
3 be stopped). cowl.
See next page for conditions which Note

4 will lead to an abnormal condition or
Warning lamp for optional tachometer
fault.
will synchronize with the LED.
8
Warning lamp
10
11
12
13
14
TOHATSU_25B-30B_E.indd 24 11/02/15 11:40

PRE-OPERATING PREPARATIONS 25
Warning indicators, faults and remedy.

Warning indicators
Engine Engine
Low- Over-
Description of faults Remedy 1
Sound Lamp (LED)
speed speed
limiter limiter
One beep On for 5 sec. Normal system test when start up

2
Continuous ON ON Water over temperature ①
Continuous (*2) ON (*2) ON (*2) Low oil pressure (*1) ② 3

Engine speed exceeds maximum
Continuous ON ON ③
4
allowable RPM
Intermittent Water temp or MAP sensor

Flashing (*2) ON (*2) ④
short beep (*2) out of range
Remarks 5
*1: In this case, oil pressure switch is "ON".
*2: It is necessary to stop the engine, if you want to stop the working indicators and
re-set the warning system. 6
Remedy
① Move to safe place quickly, and check the discharge of cooling water from the 7
water check port at idle speed and stop engine.
Remove any foreign matter on the gear case and propeller if necessary. Consult
an authorized dealer if no discharge of cooling water.
8
② Move to safe place quickly, and stop the engine.
Check the engine oil level, and add engine oil if necessary.
Consult your dealer if the engine oil level is too low or too high.
9
③ Reduce the throttle to less than half opening, and move to safe place quickly,
and stop the engine. 10
Check the propeller for bent or
damaged blades. ! CAUTION
Consult an authorized dealer if
Engine Low-speed limiter ON: Engine
11
engine shows the same result even
speed will be limited to 2,800 rpm,
after replacing propeller with new however you should not continue to run
one. engine. 12
④ Return to your home port Engine Over-speed limiter ON: Engine
immediately, and stop the engine. speed will be limited to 6,300 rpm and
Consult an authorized dealer.
engine will run rough until throttle is
reduced.
13
TOHATSU_25B-30B_E.indd 25 11/02/15 11:40

26
ENGINE OPERATION
Before starting
② Attach the fuel connector to the
Before starting engine for the first time engine connector.
1 after reassembling engine or off-season

storage, disconnect stop switch lock
The arrow mark on the primer bulb
should be facing the engine.
and pull the starter handle completely
2 out approximately 10 times in order to
prime the oil pump.
3 1. Starting
4 ! WARNING Fuel Connector
In case engine starts in gear, do not start

cruising. Stop engine immediately and ③ Feed fuel to the engine by
5 consult an authorized dealer. squeezing the primer bulb until it
is firm.
Engine side
6 Note
The engine will not start unless
7 the switch lock has been properly
connected into the emergency stop
switch.
8
Fuel tank side
! WARNING
9 Do not operate the engine with gear ④ Be sure to install the stop switch
lock to the stop switch.
case out of water.
Severe personal injury, or engine
10 damage will result.
① Loosen the air vent screw on the

11 tank cap.
Air Vent Screw
Stop Switch Lock

12
13 Stop Switch Lock
14
TOHATSU_25B-30B_E.indd 26 11/02/15 11:40

ENGINE OPERATION 27
MF, MFG, EF, EFG, EFT type

⑤ Place the shift lever in the Neutral ⑥ Set the throttle grip to "START"
position. position.
Be sure that the shift is in Neutral

1
when starting the engine.
This model is provided with start in 2
gear protection.
3
N
R
F 4
Note 5
When the engine is warm, also set the
throttle grip to "START" position.
! CAUTION 6
If the engine starts in gear, do not use it.
Contact an authorized dealer.
7
Note
8
Start-in-gear protection prevents
engine from starting at other than
neutral shift. In-gear starting of engine
will move the boat immediately,
9
potentially leading to falling down or
causing passenger(s) to be thrown
overboard. 10
11
12
13
TOHATSU_25B-30B_E.indd 27 11/02/15 11:40

28 ENGINE OPERATION
MF, MFG type EP, EPT type

Engine is equipped with a compression ⑤ Insert the main switch key.
release mechanism. ⑥ Set the control lever in the Neutral
⑦ Pull the starter handle slowly until
1 you feel engagement, keep pulling
position.
Do not raise the free accel lever
till you feel less resistance. Then when starting the engine.
2 pull it quickly.
Repeat if necessary until started.
⑦ Turn the main switch key to START
position.
⑧ Release the key when the engine
Slowly Quickly
3 has started.
The key returns to the original
position, automatically.
4 Neutral (N)
Control lever
5
Fully open
Fully closed
Free Accel lever
6 Main switch key

EF, EFG, EFT type Stop switch
⑦ Push the starter switch button.
7 ⑧ Release the button when the
engine has started.
8 Lock button
ON
OFF START
10
11
12 Note
The free accel lever can not be raised
13 when the control lever shift is in

Forward or Reverse.
14
TOHATSU_25B-30B_E.indd 28 11/02/15 11:40

ENGINE OPERATION 29
! CAUTION ! WARNING
Do not keep turning starter motor for Be careful that your clothes or other
over 5 seconds, or the battery may items do not get caught in the rotating
be consumed, potentially making the
engine starting impossible and/or
engine parts.
To prevent accident and injury, do not
1
damaging the starter. re-attach the recoil starter after the
2
If cranking over 5 seconds fails to start engine has been started using the
engine, return main switch to "ON", and emergency starter rope. Be sure to put
crank engine again after 10 seconds or the top cowl back on.
more. Immediately contact an authorized
dealer when reaching shore. 3
If the recoil starter fails to operate
◎ Remove the top cowl and the recoil ! WARNING 4
starter. Wrap a rope around the
● Be sure that no bystander(s) is
starter pulley then pull quickly to
start.
within 2 meters from back of starting
operator.
5
◎ Use a 10 mm socket wrench as a ● Do not operate the outboard motor
rope handle. with top cowl removed from the
◎ Reinstall top cowl after engine power unit, or contacting turning 6
flywheel which can lead to serious
starts.
personal injury.
7
10
11
12
13
TOHATSU_25B-30B_E.indd 29 11/02/15 11:40

30 ENGINE OPERATION
2. Warming up the engine

Engine speeds
War m the engine at low engine Idling speed after warming up.
1 speeds for about three minutes. This

allows the lubricating oil to circulate to
Remark: In case of cold engine
starting, idling speed is increased
all parts of the engine. Operating the about 300 rpm for several minutes.
2 engine without warm up shortens the
engine's life. Clutch in (In gear) Clutch off (Out of gear)
Be sure to check that cooling water is
850rpm 850rpm
3 coming out of the cooling water check
port during warm up.
PROPELLER SELECTION
4 ! CAUTION Propeller must be selected that
will allow the engine to reach
If the engine is operated without water recommended rpm when cruising at
5 discharging from the check port, the
engine may over heat.
wide-open throttle.
Wide-open throttle rpm range

6 25 30
5,000∼6,000rpm 5,250∼6,250rpm
7
Cooling
water check Genuine propellers are listed on
port PROPELLER TABLE of this manual.
8
9
! CAUTION
10 Be sure to stop engine immediately
if cooling water check port is not
discharging water, and check if cooling
11 water intake is blocked. Operating
engine could lead to overheating
potentially leading to engine damage.
12 Consult an authorized dealer if the
cause cannot be found.
13
14
TOHATSU_25B-30B_E.indd 30 11/02/15 11:40

ENGINE OPERATION 31
3. Forward and reverse MF/MFG and EF/EFG/EFT type
! WARNING
N
1
Before shifting into forward or reverse, R
make sure that boat is properly moored
F
and outboard motor can be steered
fully to the right and left. Make sure that 2
no swimmer(s) is ahead or astern of the
boat.
Shift Lever
3
! WARNING ! WARNING 4
● Attach other end of emergency
Severe damage, and personal injury,
stop switch tether to the operator's
may occur if shifting at high engine
clothing or arm and keep it attached
during cruising.
speed. 5
Engine must be in the slow idle position
● Do not attach the tether to a part of
before shifting is attempted.
clothing that can be torn easily when
pulled. 6
● Arrange the tether so that will not be
■ Forward
caught by any object when pulled.
Turn the throttle grip to reduce engine
● Be careful not to pull the tether
accidentally during cruising. speed. When the engine reaches 7
Unintentional stop of engine can trolling (or idling) speed, quickly pull
cause loss of control of outboard
motor. Rapid loss of engine power
the shift lever to the Forward position.
8
can lead to falling down or causing
passenger(s) to be thrown overboard. ■ Reverse
Reduce engine speed, when the
engine reaches trolling (or idling)
9
speed, quickly push the shift lever to
Note the Reverse position. 10
Do not increase engine speed
unnecessarily in reverse. ! WARNING 11
Before shifting, make sure that no
swimmer(s) or obstacle(s) is ahead or
astern of the boat.
12
13
TOHATSU_25B-30B_E.indd 31 11/02/15 11:40

32 ENGINE OPERATION
! CAUTION ■ Forward
Quickly push the control lever to the
Be sure to warm up engine well before
starting cruise. Operating cold engine
Forward (F) position 32˚, where the
gear is connected, while lifting up on
1 may cause damage to your motor.
the lock button located at the bottom
of the control lever grip. Further
2 Note shifting will open the throttle.
Idle speed may be higher during ■ Reverse

warming up of engine. If shifted to
3 Forward or Reverse during warming
Quickly pull the control lever to the
up, it may be difficult to shift back to Reverse (R) position at 32˚, where the
neutral. In such case, stop engine, gear is connected, while lifting up on
4 shift to neutral, and restart engine to
warm up.
the lock button located at the bottom
of the control lever grip. Further
shifting will open the throttle.
5
Note
Note
Frequent shifting to forward or reverse
6 can accelerate wear or degradation The control lever is inoperative unless
of parts. In such case, replace gear the free accel lever is in the fully
oil earlier than the period specified. closed position.
7
EP, EPT type Note
8 Control Lever
Reduce the engine speed when
the control lever is in Neutral and
do not increase the engine speed
9 Lock Button unnecessarily.
10 Neutral
d (N) Re
ar Shif
t Shif
t ( verse
rw
Fo (F) R)
11 ut
abo °
2
abou
32° t
Th
3
ro
ttl
tle
e
Ful
lly
los
Fu en
rot
ly c
ly c
12 op
Th
los
Ful
e
Free
Fully Accel
open Lever
13
14
TOHATSU_25B-30B_E.indd 32 11/02/15 11:40

ENGINE OPERATION 33
4. Stopping EP, EPT type
MF, MFG, EF, EFG, EFT type

1
ON
2
OFF
START
4
Stop switch Stop Switch Lock Stop switch lock
① Turn the throttle grip to the slow (N) 5

position.
② Put the shift lever in the Neutral
position. 6
Run the engine for 2-3 minutes at
idling speed if it has been running
at full speed. 7
③ Push the stop switch to stop the
engine or release the stop switch
lock.
8
① Put the shift lever in the Neutral
! WARNING position and run the engine for 2-3
minutes at idling speed if it has
9
● Do not shift into Reverse during been running at full speed.
planing, or control will be lost leading
to serious personal injury, boat ② Turn the main switch key to the 10
may swamp, and/or hull may be OFF position.
damaged.
● Do not shift into Reverse during
cruising, or control may be lost,
Notes 11
falling down or causing passenger(s) ● After stopping the engine, close the
to be thrown overboard. Leading to air vent screw on the tank cap.
serious personal injury, and steering ● Disconnect the fuel connector of 12
system and/or shifting mechanism the engine or the fuel tank.
may be damaged. ● Disconnect the battery cord of the EF
or EP type engine, if the engine will
not be used for more than 3 days.
13
TOHATSU_25B-30B_E.indd 33 11/02/15 11:40

34 ENGINE OPERATION
5. Trim angle
The trim angle of the outboard motor
1 can be adjusted to suit the transom

angle of the hull, and load conditions.
Choose an appropriate trim angle
2 that will allow the anti-ventilation plate
to run parallel to the water surface
during operation.
3
MF, EF, EFG, EFT, EP type
■ Proper trim angle Higher Thrust rod
4 The position of the thrust rod is Lower

correct if the hull is horizontal during
operation. ! WARNING
5 Perpendicular to the
water surface
● Do not put hand or finger in between
outboard motor body and clamp
6 bracket when adjusting trim angle to

prevent injury in case the outboard
motor body falls.
● Unsuitable trim position can cause
7 loss of control of boat.
When testing a trim position, run
■ Improper trim angle boat slow initially to see if it can be
Set the thrust rod lower if the bow of
8 the boat rises above horizontal.
controlled safely.
9 ! WARNING
Excessive trim up or down may lead
to unstable boat operation, potentially
10 causing the steering difficulty that leads
to accident during cruising.
■ Improper trim angle ● Do not cruise at high speed if
11 Set the thrust rod higher if the bow of improper trim position is suspected.
Stop the boat and readjust trim
the boat is below horizontal.
angle before continuing cruise.
12 ● For outboard motor model with PTT

switch on the bottom cowl, do not
operate the switch during cruising,
or control of boat may be lost.
13
14
TOHATSU_25B-30B_E.indd 34 11/02/15 11:40

ENGINE OPERATION 35
EFT, EPT type

The provided Power tilt makes tilt- ■ How to use the trim meter (option)
up/down electrically. It may be used When the trim angle is set as desired,
as a power trim and tilt when the
outboard motor is used with the light
take a reading off the trim meter, and
record it for future reference.
1
load condition. In this case, it can be
adjusted to set the desired trim angle 2
of the outboard motor in relation to
the transom shape, planning speeds
and load. It is imperative that the trim 3
angle is adjusted correctly. Incorrect
adjustment will cause the boat to
sway, deteriorate engine performance 4
and may cause unsafe steering
conditions.
5
8°
Trim angle
7
74°
8
Tilt range
! CAUTION
The Power Trim & Tilt can be set to 9
any trim angle, however, avoid cruising
with the outboard motor tilted in the
tilt range. Operating the boat in this 10
manner, the outboard motor may ingest
air into the water cooling system,
resulting in engine overheating.
11
12
13
TOHATSU_25B-30B_E.indd 35 11/02/15 11:40

36 ENGINE OPERATION
■ Improper Trim Angle (bow rises too ■ Proper Trim Angle

high) The trim angle is optimum when the
1 If the trim angle is excessive, the

bow will rise out of the water and the
boat is parallel to the water surface
while running.
speed will decrease.
2 Furthermore, the bow may sway or
the bottom may slam the water while
! WARNING
cruising. ● Do not put hand or finger in between
3 In this case, decrease the trim angle outboard motor body and clamp
bracket when adjusting trim angle to
by pressing the switch on the remote
prevent injury in case the outboard
control level to "DN". motor body falls.
4 Down
(DN)
● Unsuitable trim position can cause
loss of control of boat.
When testing a trim position, run
5 boat slow initially to see if it can be
controlled safely.
6
! WARNING
7 Excessive trim up or down may lead
to unstable boat operation, potentially
■ Improper Trim Angle (bow dips into causing the steering difficulty that leads
the water) to accident during cruising.
8 If the trim angle is too small, the bow
● Do not cruise at high speed if
improper trim position is suspected.
will dip into the water, the speed Stop the boat and readjust trim
9 will decrease, and water may enter
the boat. In this case, the trim angle
angle before continuing cruise.
● For outboard motor model with PTT
should be increased by pressing the switch on the bottom cowl, do not
operate the switch during cruising,
10 switch on the remote control lever to
"UP".
or control of boat may be lost.
UP
11
12
13
14
TOHATSU_25B-30B_E.indd 36 11/02/15 11:40

ENGINE OPERATION 37
6. Tilt up, tilt down and shallow water operation ! WARNING

● Do not put hand or finger in between
MF, EF, EP type outboard motor body and clamp
bracket when adjusting trim angle to 1
! WARNING prevent injury in case the outboard
motor body falls.
● When tilting up outboard motor with
When tilting up or down, be careful not
to place your hand between the swivel fuel joint for over a few minutes, 2
bracket and the stern bracket. be sure to disconnect fuel hose or
Be sure to tilt the outboard motor down close fuel cock, or fuel may leak,
slowly. potentially catching fire. 3
Note
! CAUTION 4
Stop the engine before tilting up.
Do not tilt up outboard motor during
■ Tilt up
operation, or engine may be damaged
from overheating due to lack of 5
Push the reverse lock lever down until sufficient cooling water.
it stops. (This is the tilt up position.)
Now, tilt the outboard motor all the 6
way up until it is locked in place. ■ Tilt down
Pull the reverse lock lever upward
until it stops. (This is the tilt down 7
position.) Now, lift up the outboard
motor slightly, and then allow gravity
to lower it for you.
8
Reverse lock lever
Tilt Down 9
position
10
Reverse lock lever
11
Tilt Up position
Tilt Down 12
13
TOHATSU_25B-30B_E.indd 37 11/02/15 11:40

38 ENGINE OPERATION
■ Shallow water operation

② Return to normal running position:
! WARNING Put the reverse lock lever in the tilt
1 During shallow water operation, be

down position, slightly lift up the
outboard motor, and then put it
careful not to place your hand between
the swivel bracket and the stern down.
2 bracket.
Be sure to tilt the outboard motor down Tilt Down
Reverse lock lever
slowly. position
3
Note
4 Slow down to trolling speed, and shift

into neutral before setting outboard
motor to shallow water drive position.
5
Tilt Up position
Tilt Down
! WARNING
! CAUTION
6 ● Run at lowest possible speed when
using shallow water drive. While in shallow water drive position,
● Tilt lock is disabled when in shallow do not operate the outboard motor in
water drive position. reverse. Operate the outboard motor at
7 ● When driving shallow water, be slow speed and keep the cooling water
careful not to strike outboard motor intake submerged.
against sea bottom, or propeller may
8 be pushed out of water, resulting in
loss of control.
9 ① Shallow water running position:

Put the reverse lock lever in the tilt
Sub Water
Inlet
up position, and tilt up the outboard
10 motor to put the outboard motor in
the shallow water running position.
Reverse lock lever
11 ! CAUTION
Do not overtilt outboard motor
12 when driving shallow water, or air

may be sucked through subwater
inlet, potentially leading to engine
overheating.
13
14
TOHATSU_25B-30B_E.indd 38 11/02/15 11:40

ENGINE OPERATION 39
MGF, EFG type (Gas Assist type) ! WARNING

Do not tilt up or down outboard motor
■ Tilt up when swimmer(s) or passenger is near
M o v e ( U P ) l o c k l e v e r t o " F re e "
position. Fully tilt up the outboard
to prevent them from being caught
between outboard motor body and
1
motor. While keeping the outboard clamp bracket in case the outboard
2
motor in full tilt up position, move, motor body falls.
(DOWN) lock lever to "Lock" position.
For safety, set the tilt stopper into the
set-up position, although the outboard ! WARNING 3
motor is kept in the tilt up position When tilting up outboard motor with
after the lock lever is moved (DOWN) fuel joint for over a few minutes, be
to "Lock" position. sure to disconnect fuel hose or close
fuel cock, or fuel may leak, potentially
4
catching fire.
■ Tilt down
M o v e ( U P ) l o c k l e v e r t o " F re e " 5
position. Release the tilt stopper from
the set-up position while slightly tilting
! CAUTION
up outboard motor. Release outboard Do not tilt up outboard motor while 6
motor down to thrust rod. Move engine operates, or no cooling water
may be fed, leading to engine seizure
(DOWN) lock lever to "Lock" position
after the outboard motor is completely
due to overheating. 7
tilted down.
Free position
8
10
Lock position
11
12
13
TOHATSU_25B-30B_E.indd 39 11/02/15 11:40

40 ENGINE OPERATION
■ Shallow water operation
! WARNING
1
Sub Water
During shallow water operation, be Inlet
careful not to place your hand between
the swivel bracket and the stern bracket.
2 Be sure to tilt the outboard motor down
slowly.
3 ① Shallow water running position ! CAUTION

Move (UP) lock lever to "Free" Do not overtilt outboard motor
position. Tilt up outboard motor when driving shallow water, or air
4 into desired shallow water running. may be sucked through subwater
inlet, potentially leading to engine
While keeping the outboard motor
overheating.
i n t h e d e s i re d s h a l l o w w a t e r
5 running position, move (DOWN)
lock lever "Lock" position.
EFT, EPT type
6 ① Operate the Power Trim & Tilt switch
and tilt the outboard motor up.
7 UP
8 Tilt Stopper DN
The outboard motor can also be

9 ② Return to normal running position
Move (UP) lock lever to "Free"
tilted up using the switch provided
under the bottom cowl.
position. Outboard motor moves
10 down to thrust rod.
Move (DOWN) lock lever to "Lock"
UP
position.
11 DN
! CAUTION
12 While in shallow water drive position,
It is possible to tilt up or down in spite of
do not operate the outboard motor in
Reverse. Operate the outboard motor main switch "ON" or "OFF".
13 at slow speed and keep the cooling

water intake submerged.
14
TOHATSU_25B-30B_E.indd 40 11/02/15 11:40

ENGINE OPERATION 41
! WARNING
◎ If the battery is dead, and the
Do not tilt up or down outboard motor
when swimmer(s) or passenger is near to
power trim & tilt switch thus
prevent them from being caught between
outboard motor body and clamp bracket
inoperative, turn the manual valve
a few turns in the Manual direction.
1
in case the outboard motor body falls. This will allow manual tilting of the
outboard motor. 2
! WARNING
When tilting up outboard motor with fuel
joint for over a few minutes, be sure to
3
disconnect fuel hose or close fuel cock,
or fuel may leak, potentially catching fire.
4
! CAUTION
Do not tilt up outboard motor while
POWER 5
engine operates, or no cooling water
may be fed, leading to engine seizure
due to overheating. 6
② Lock the tilt with the Tilt stopper

MANUAL
7
after the outboard motor has been
tilted up.
8
10
Tilt Stopper
Note 11
For U.S.A. market only
High altitude: 12
When engine operates at high altitude engine may need to have a high altitude kit
installed. Otherwise, operating the engine at high altitude may increase its emissions
and decrease fuel efficiency and performance. Please see "LIMITED WARRANTY
INFORMATION" for more detail. 13
TOHATSU_25B-30B_E.indd 41 11/02/15 11:40

42
REMOVING AND CARRYING THE OUTBOARD MOTOR

1. Removing the outboard motor 3. Storing the outboard motor
① Stop the engine. Outboard motor should be stored in a

② Disconnect the fuel connector,
1 the remote control cables and the
vertical position.
battery cords from the outboard Note

2 motor.
③ Remove the outboard motor from If the outboard motor must be laid
down be sure the tiller handle faces
boat and completely drain the
down as shown in the drawing above.
3 water from the gear case. Elevate power unit 2 inches to 4
inches if traveling to avoid oil spillage.
! CAUTION
4 Engine may be hot immediately after
operating and could cause burns if ! CAUTION
touched. Allow Engine to cool down
5 before attempting to carry the outboard. Do not carry or store outboard motor in
any of positions described below.
Otherwise, engine damage or property
6 2. Carrying the outboard motor damage could result from leaking oil.
Keep the outboard motor in a vertical

position when carrying.
7
10
11
! WARNING
12
Close air vent screw of fuel tank and
fuel cock before carrying or storing
13 outboard motor and fuel tank, or fuel

may leak, potentially catching fire.
14
TOHATSU_25B-30B_E.indd 42 11/02/15 11:40

43
TRAILERING
MGF, EFG type (Gas Assist type) ! CAUTION
! WARNING The tilt support device supplied on your
outboard motor is not intended for towing.
Do not go under outboard motor tilted
up even if it is supported by support
It is intended to support the outboard motor
while the boat is docked, beached, etc.
1
bar, or accidental fall of outboard motor
2
could lead to severe personal injury.
! CAUTION
! WARNING When trailering the outboard motor should
Close air vent screw of fuel tank and fuel cock

be in a vertical (normal running) position, fully
down. Trailering in the tilted position may cause
3
before carrying or storing outboard motor and fuel damage to the outboard motor, boat, etc.
tank, or fuel may leak, potentially catching fire. If trailering with outboard motor fully down
is not available (the gear case skeg is too 4
close to the road in a vertical position), fix the
! WARNING outboard motor securely using a device (like
When taking outboad motor from a transom saver bar) in the tilted position.
5
package or removing outboad motor from
the boat, never release the lock lever. If
the lock lever is released, it will very easy
for the clamp bracket to spring up to the 6
tilting direction because it is not fixed.
7
! WARNING
Never attempt to disassemble shock
absorber of gas assist tilt system. It is 8
dangerous because high pressure gas
is included in the shock absorber. ! WARNING
*Care must be taken so as not to
Please disconnect fuel connector 9
except when operating engine.
release lock lever by accident. Fuel leakage is a fire or explosion hazard,
*For more safety, tie the clamp bracket which can cause serious injury or death. 10
to the outboard motor with a rope.
*Pay attention to the tilting direction so as not
to be injured by the springing stern bracket. 11
Lock lever 12
Clamp bracket
13
LOCK
Tilting
Rope direction
TOHATSU_25B-30B_E.indd 43 11/02/15 11:40

44
ADJUSTMENT
1. Steering friction 2. Throttle grip
Adjust this lever to achieve the Friction adjustment of the throttle
1 desired steering friction (drag) on

the tiller handle. Move lever towards
grip can be made with the throttle
adjustment screw.
(a) to tighten friction and move lever
2 towards (b) to loosen friction.
Steering
friction lever Lighter
3
Throttle adjustment
screw
4 Heavier
5 a
Heavier
b
Lighter
3. Remote Control Lever Load
6 ! WARNING (Throttle friction adjustment screw)
To adjust the load of the remote
Do not overtighten the throttle grip or
control lever, turn the throttle friction
7 remote control tensioner or it could result
in difficulty of movement resulting in the adjustment screw on the front of
loss of control causing an accident and the remote control. Turn clockwise
could lead to severe injury. to increase the load and counter-
8 clockwise to decrease it.
10 Lighter Heavier
11
Throttle friction
adjustment screw
12
13
14
TOHATSU_25B-30B_E.indd 44 11/02/15 11:40

ADJUSTMENT 45
4. Trim Tab Adjustment ! WARNING

● Inappropriate adjustment of trim tab
If straight-line cruising can not be could cause steering difficulty. After
achieved, adjust the trim tab located
under the anti-ventilation plate.
installing or readjusting trim tab,
check if steering load is even.
1
◎ If the boat veers toward the right, ● Tighten trim tab bolt to specified
2
direct the trim tab towards A. torque.
◎ If the boat veers toward the left,

direct the trim tab towards B.
! WARNING 3
● Be sure that outboard motor is
B
secured to transom or service
stand, or accidental drop or fall of 4
A outboard motor could lead to severe
personal injury.
Trim tab ● Be sure to lock outboard motor if
it is tilted up, or accidental fall of
5
outboard motor could lead to severe
personal injury.
Notes
● Do not go under outboard motor 6
tilted up and locked, or accidental
fall of outboard motor could lead to
● The trim tab also acts as an anode
to prevent electrolytic corrosion.
severe personal injury. 7
Therefore do not paint or grease
this part.
● After adjustment securely tighten
the trim tab fixing bolt.
8
● Check for looseness of the bolt and
the trim tab at regular intervals.
9
Notes 10
Due to corrosion, the trim tab will
wear down over time.
The trim tab should be replaced when 11
it has eroded 2/3 of it's regular size.
12
13
TOHATSU_25B-30B_E.indd 45 11/02/15 11:40

46
INSPECTION AND MAINTENANCE

Care of your outboard motor EPA Emissions Regulations
To keep your outboard motor in the EPA (United States Environmental
best operating condition, it is very Protection Agency) has emission
1 important that you perform daily and

periodic maintenance as suggested
regulations regulating air pollution
from new outboard motors. All new
in the maintenance schedules that outboard motor manufactured by us
2 follow. are certified to EPA as conforming to
the requirements of the regulations.
! CAUTION This cer tification depends upon
3 ● Your personal safety and that of
factory standards. Therefore, factory
specifications must be followed when
your passengers depends on how
servicing emission related controls,
well you maintain your outboard
4 motor. Carefully observe all of or making adjustments. Maintenance,
the inspection and maintenance replacement, or repair of the emission
procedures described in this control devices and systems may be
5 section.
● The maintenance intervals shown in
performed by any marine SI (Spark
Ignition) engine repair establishment
the checklist apply to an outboard
or individual.
6 motor in normal use. If you use
your outboard motor under severe
conditions such as frequent
full-throttle operation, frequent
7 operation in brackish water, or
for commercial use, maintenance
should be performed at shorter
8 intervals. If in doubt, consult your

dealer for advice.
● We strongly recommend that you
use only genuine replacement parts
9 on your outboard motor. Damage
to your outboard motor arising from
the use of other than genuine parts
10 is not covered under the warranty.
11
12
13
14
TOHATSU_25B-30B_E.indd 46 11/02/15 11:40

INSPECTION AND MAINTENANCE 47
1. Daily Inspection
Perform the following checks before

! WARNING
and after use.
1
Do not use outboard motor if any
abnormality is found during pre-operation
check or it could result in severe damage
to the motor or severe personal injury. 2
Item Points to Check Remedy

3
● Check the amount of fuel in the tank. Replenish
Fuel System ● Check for debris or water in the fuel filters. Clean or replace
● Check the rubber hoses for fuel leakage. Replace
4
Engine Oil ● Check the oil level. Fill oil
● Check that the main switch functions normally. Replace

● Check that the battery electrolyte level and specific Replenish or recharge 5
gravity are normal.
● Check for loose connections on the battery terminal. Retighten
6
Electrical ● Check that the stop switch functions normally and make Remedy or replace
Equipment sure the lock plate is there.
● Check cords for loose connections and damage. Correct or replace
● Check the spark plugs for dirt, wear and carbon build-up. Clean or replace
● Check the warning horn (one beep) and warning LED
lamp (ON for 5 to 7 secs.) when start up. 7
● Check the rope for wear and chafing. Replace
Recoil Starter
● Check the ratchet engagement. Correct or replace
8
● Check that clutch engages correctly when operating the Adjust
shift lever.
Clutch and
● Visually Check propeller for bent or damaged blades.
9
Replace
Propeller System
● Check the propeller nut is tightened and the split pin is
present.
Installation of ● Check all the bolts attaching the motor to the boat.
Motor ● Check the thrust rod installation.
Tighten
10
Power Trim & Tilt ● Check working of the tilt up and down of the motor.
Cooling Water
● Check that cooling water is discharged from the cooling
water check port after the engine has started.
Repair 11
● Check that there are tools and spare parts for replacing
Tools and Spares spark plugs, the propeller, etc.
● Check that you have the spare rope. 12
Steering Devices ● Check the operation of the steering handle. Repair
Other parts
● Check if the anode is securely installed. Repair if necessary 13
● Check the anode for corrosion and deformation. Replace
TOHATSU_25B-30B_E.indd 47 11/02/15 11:40

48 INSPECTION AND MAINTENANCE
Maintaining engine oil Notes

If the engine oil is low, the life of the
Consult with an authorized dealer
engine will be shortened significantly. if the engine oil is milky color, or
1 ■ Checking oil level
appears contaminated.
① Stop the engine and set it in a

2 vertical position.
② Remove the top cowl.
■ Replenishing engine oil
If the oil level is low, or at lowest mark,
③ Remove the dipstick. add recommended oil to the upper
3 ④ Wipe oil off the oil dipstick with a dipstick mark.
clean rag.
⑤ Put in the dipstick. ! CAUTION
4 ⑥ Take out the dipstick and check
the oil level. ● Do not add engine oil of brand and
grade other than existing one. In
⑦ Replace the dipstick.
5 Filler cap
case engine oil of other brand or
grade is added, drain all oil and ask
dealer for treatment.
● In case other than engine oil such
6 Dipstick as gasoline is put in the oil chamber,
empty the chamber and ask dealer
for treatment.
7 ● When replenishing engine oil, be
careful not to allow entry of foreign
matters such as dust and water into
oil chamber.
8 ● Wipe off engine oil well immediately
if spilled.
● Do not replenish engine oil over
9 upper limit. If overfilled, remove oil
to upper limit. If engine oil is over
the upper limit, it can leak potentially
leading to engine damage.
10
11 Upper Level 1,800ml
Lower Level 1,500ml
12
Notes
13 The oil level should be checked when

the engine is cold.
14
TOHATSU_25B-30B_E.indd 48 11/02/15 11:40

Washing outboard motor

If outboard motor is used in salt ■ Use a drive cleaner
water, brackish water or water with a ① Remove propeller and thrust holder
high acidic level, use fresh water to
remove salt, chemicals or mud from
(refer to Propeller Replacement).
② Seal the sub water inlet with tape.
1
exterior and cooling water passage ③ Install the drive cleaner on the
after every cruising or before storing water inlet portion. 2
outboard motor for long time. Before ④ Attach a water hose to the drive
flushing, remove the propeller and the cleaner.
forward thrust holder. Turn on the water and adjust the 3
flow.
! CAUTION ⑤ Start the engine and run it at idle
Keep cooling water passage free of

speed in neutral position. 4
⑥ Check for a steady stream of water
clogs, or lack of cooling water flow
flowing out of the cooling water
could lead to engine overheating,
potentially resulting in engine trouble. check port. Continue flushing the 5
outboard motor for 3 to 5 minutes,
carefully monitoring water supply
Notes at all times. 6
⑦ Stop the engine, turn off the water,
It is recommended to check chemical and remove the drive cleaner and
properties of water on which your tape. 7
outboard motor is regularly used.
Reinstall the propeller.
8
! WARNING Drive
cleaner
Do not start engine without removing
propeller, or accidentally turning
9
propeller could cause personal injury. Sub water inlet
10
! WARNING Water inlet
Never start or operate the engine 11

indoors or in any space which is not
well ventilated. Exhaust gas contains
carbon monoxide, a colorless and
! CAUTION 12
odorless gas which can be fatal if Keep engine at idle speed during
inhaled for any length of time. flushing.
13
TOHATSU_25B-30B_E.indd 49 11/02/15 11:40

Replacing the propeller

■ Use flushing attachment. A worn-out or bent propeller will lower
① Remove propeller and thrust holder the motor's performance, and cause
1 (refer to Propeller Replacement).

② Seal the water inlet and sub water
engine trouble.
Before removing the propeller, remove
inlet with tape. the spark plug caps from the spark
2 ③ Remove the water plug from the
outboard motor, and screw in the
plugs to protect against personal
injury.
flushing attachment.
3 ④ Attach a water hose to the flushing ! WARNING
attachment. Turn on the water and
Do not begin propeller removal and
adjust the flow. installation procedure with spark
4 ⑤ Start the engine and run it at idle plug caps attached, shift in forward
speed in neutral position. or reverse, main switch at other than
⑥ Check for a steady steam of water "OFF", engine stop cord attached to
5 flowing out of the cooling water
the switch, and starter key attached, or
engine could accidentally start leading
check port. to serious personal injury. Disconnect
Continue flushing the outboard battery cable if possible.
6 motor for 3 to 5 minutes, carefully
monitoring water supply at all ① Remove the split pin, propeller nut
times. and washer.
7 ⑦ Stop the engine, tur n off the ② Remove the propeller and thrust
water, and remove the flushing holder.
attachment and tape. ③ Apply genuine grease to the
8 Reinstall the propeller. propeller shaft before installing a
new propeller.
9 ④ Install the thrust holder, propeller,

washer and propeller nut onto the
shaft.
10 ⑤ Install a new split pin into the nut
hole and bend it.
11 Propeller Washer
Propeller
Flushing shaft
12 attachment
Split pin
Nut
13
Thrust
holder
14
TOHATSU_25B-30B_E.indd 50 11/02/15 11:40

! WARNING Notes
Do not hold propeller with hand(s) When inspecting the plug, always
when loosening or tightening propeller clean the gasket surface and use a
nut. Put a piece of wood block between
propeller blade and anti-ventilation
new gasket. Wipe off any dirt from the
threads and screw in the spark plug
1
plate to hold propeller. to the correct torque.
2
① Stop the engine.
! CAUTION ② Remove the top cowl.
● Do not install propeller without ③ Remove the spark plug caps. 3
thrust holder, or propeller boss ④ Remove the spark plugs by turning
could be damaged. it counter-clockwise, using a 5/8"
● Do not reuse split pin.
● After installing split pin, spread the
socket wrench and handle. 4
⑤ Attach spark plug and tighten to
pin apart to prevent it from falling
specified torque.
5
out which could lead to the propeller
coming off during operation.
Use spark plug NGK DCPR-6E.
Replacing the spark plugs 6

Electrode
! WARNING Spark gap 7
(0.8 to 0.9 mm, 0.031 to 0.035 in)
● Do not reuse spark plug with
damaged insulation, or sparks
can leak through crack, potentially
leading to electric shock, explosion
Notes 8
and/or fire. ◎ Spark plug torque :
● Do not touch spark plugs
9
18.0Nm(13.3ft-lb)(1.84kgf-m)
immediately after stopping engine If a torque-wrench is not available
as they will be hot and could cause when you are fitting a spark plug, a
severe burns if touched. Allow good estimate of the correct torque
motor to cool down first. is 1/4 to 1/2 a turn past finger-tight. 10
Have the spark plug adjusted to the
If the spark plug(s) is fouled, has correct torque as soon as possible
carbon build up, or is worn, it should with a torque-wrench.
11
be replaced.
When reusing spark plugs, remove
dirt from the electrodes and adjust 12
spark gap to specification.
13
TOHATSU_25B-30B_E.indd 51 11/02/15 11:41

Replacing the anode Checking and Refilling Oil in the

A sacrificial anode protects the Power Trim & Tilt.
outboard motor from galvanic ① Check the oil level of the reservoir
1 corrosion. Anode is located on the gear

case and the cylinder. When the anode
tank as shown on the right while
the tank is kept in a ver tical
is eroded more than 2/3, replace it. position. Tilt the outboard motor up
2 to check the oil level in the tank.
Remove the oil cap by turning
Notes
counter-clockwise, then check if
3 ● Never grease or paint the anode.
● At each inspection re-tighten the
the oil level reaches the bottom
line of the plug hole.
anode attaching bolt. As it is likely
to be subjected to electrolytic
4 corrosion.
Oil cap
5
Anode
6 (Trim tab)
Oil level
8
! WARNING
9 Anode
● Be sure that outboard motor is
secured to transom or service
stand, or accidental drop or fall of
10
personal injury.
● Be sure to lock outboard motor if
it is tilted up, or accidental fall of
11 Anode
personal injury.
● Do not go under outboard motor
12 tilted up and locked, or accidental

severe personal injury.
13 Anode
(installed on the back of cap)
14
TOHATSU_25B-30B_E.indd 52 11/02/15 11:41

! CAUTION
Do not unscrew the oil plug with the
outboard motor tilted down. Pressurized
oil in the oil tank may spurt out. 1
② Recommended oil 2
Use an automatic transmission
fluid or equivalent.
Recommended oils are as shown 3
below.
ATF Dexron III
4
③ Air purging from the Power Trim
and Tilt unit.
Entrapped air in the Power Trim 5
& Tilt unit will cause poor tilting
movement and increased noise.
With the outboard motor mounted 6
on the boat, set the manual release
valve to the Manual side, and
tilt the outboard motor manually 7
up/down 5-6 times while checking
the oil level. When done, close
the valve by turning it clockwise
8
towards the Power side.
9
10
11
POWER
12
13
MANUAL
TOHATSU_25B-30B_E.indd 53 11/02/15 11:41

2. Periodic Inspection
It is important to inspect and maintain your outboard motor regularly. At each
1 interval on the chart below, be sure to perform the indicated servicing. Maintenance
intervals should be determined according to the number of hours or number of
months, whichever comes first.
2 Inspection intervals
Description First 20 Every 50 Every 100 Inspection procedure Remarks

3 hours of hours of hours of
1 month 3 months 6 months
Fuel filter ○ ○ ○ Check and clean or Replace if necessary.
4 Fuel
*High pressure fuel filter Replace every 200 hrs or 2 years Entire cartridge
System Check and clean or Replace if

Piping/Hoses ○ ○ ○
necessary.
5 Fuel tank ○ ○ Clean
Check gaps.
0.8-0.9mm
Ignition Spark plug ○ ○ Remove carbon deposits or Replace
(0.031-0.035in)
if necessary.
6 Starting
*Starter rope ○ ○ ○ Check for wear or chafing
System Check for salt deposits and

*Starter motor ○
the battery cable condition.
7 Engine oil ○ ○ Replace if necessary.
Oil filter Replace every 200 hrs or 2 years Entire cartridge
Engine *Valve Clearance ○ ○ Check & adjust

8 *Timing belt ○ Check and Replace if necessary.
*Air filter Replace every 200 hrs or 2 years for ISC
9 Propeller ○
Replace
○ ○
Replace
Check for bent blades, damage, wear.
Change or replenish-oil and check 280mL

Lower Gear oil
○ ○ for water leaks. (9.5 fl.oz.)
Unit
10
Replace impeller
*Water pump ○ ○ Check for wear or damage.
every 12 months.
Check & replenish oil, manually

*Power trim & tilt ○ ○
operate
11 *Warning system ○ ○ Check function
Bolts and Nuts ○ ○ ○ Retighten
Sliding and Rotating Parts.
12
○ ○ ○ Apply and pump in grease.
Grease Nipples
Outer Equipment ○ ○ ○ Check for corrosion.
Replace if
Anode ○ ○ Check for corrosion and deformation.
13 necessary.
*Have this handled by your dealer.
14
TOHATSU_25B-30B_E.indd 54 11/02/15 11:41

Notes
Yo u c a n a l s o u s e N M M A F C - W
Your outboard motor should receive
careful, and complete inspection at
certified 4-stroke outboard oil below.
300 hours. This is the best time for
major maintenance procedures to be
10W-30: is recommended for use in
all temperature.
1
carried out. 25W-40: may be used at temperatures
above 4˚C (40˚F). 2
Replacing engine oil
Engine oil mixed with dust or water 20W−40, 20W−50
will dramatically shorten the life of the 3
engine. ENGINE 15W−40, 15W−50
To change engine oil: OIL
① Stop the engine and set it in a tilted

10W−40, 10W−50
4
position. 10W−30
② Remove the top cowl and oil filler
cap. Allow it to cool. -30 -20 -10
-22 -4 14
0
32
10
50
20
68
30
86
40
96
˚C
˚F
5
③ Turn the steering on the outboard Atmospheric temp.
motor so that the drain hole is
facing downward. 6
④ Put a oil drain pan under the oil
! CAUTION
drain screw.
⑤ Remove the oil drain screw and
Use of engine oils that do not meet
these requirements will result in reduced 7
completely drain oil from the engine life, and other engine problems.
engine.
⑥ Tighten the oil drain screw.
8
⑦ Reset the engine in a vertical
position.
⑧ Fill the engine through filler port
9
Oil volume needed for
with recommended oil (see chart complete oil replacement
below) to the upper dipstick mark.
Without 10
⑨ Tighten the oil filler cap. With oil filter
oil filter
replacement
replacement
Filler port
Upper limit
(Max.)
1,800ml 1,600ml
(1.90 US qt.) (1.69 US qt.)
11
Drain hole Lower limit 1,500ml 1,300ml
(Min.) (1.58 US qt.) (1.37 US qt.)
12
13
TOHATSU_25B-30B_E.indd 55 11/02/15 11:41

! CAUTION Replacing oil filter

① Drain oil from the engine.
You may be injured due to high engine
temperatures if you fill engine oil just ② Place a rag or towel below the oil
1 after stopping. Changing engine oil

should be done after the engine has
filter to absorb any spilled oil.
③ Unscrew old filter by turning the
been cooled. filter to the left.
2 ④ Clean the mounting base. Apply
film of clean oil to filter gasket.
! CAUTION Do not use grease. Screw new filter
3 ● Do not overfill engine oil, or engine
on until gasket contacts base, then
oil could leak and/or engine could be tighten 3/4 to 1 turn.
damaged. If engine oil level is over
4 upper limit marks of oil gauge, drain
oil to level lower than upper limit. P/N 3AC-99090-0
● Be sure that outboard motor is in P/N 3AC99090M
(US.CANADA Only)
upright and level position when
5 checking or changing oil.
● Stop engine immediately if low oil Oil filter wrench
pressure warning lamp is lit or oil
6 leak is found, or engine could be
severely damaged. Consult dealer.
7
Notes
8 ● If any amount of water is found in

engine oil, making it milky white,
consult dealer.
● If engine oil is contaminated with
9 fuel, emitting strong fuel smell,
consult dealer. Oil filter
● Some oil dilution is normal if High pressure fuel filter Fuel filter
10 engine is idled or trolled for long
periods, especially in cooler water
temperatures.
11
12
13
14
TOHATSU_25B-30B_E.indd 56 11/02/15 11:41

Cleaning the fuel filters and the

fuel tank ② If present, disconnect hoses from
Fuel filters are provided inside the fuel the fuel connector (male) and the
tank and engine. fuel pump.
③ Remove the cup, filter and O-rings
1
! WARNING from the fuel filter body.
Gasoline and its vapors are very

④ Remove fuel and any water or 2
foreign matter from the cup, filter
flammable and can be explosive.
● Do not start this procedure while and hoses.
engine is operating or hot even after ⑤ Reset all parts. 3
stopping it.
● Place fuel filter away from every ■ High pressure fuel filter (for engine)
source of ignition such as sparks or
open flames.
Entire cartridge should be replaced 4
● Wipe off gasoline well immediately if every 200 hours of operation or 2
spilled. years.
● Install fuel filter with all related parts “IN”mark 5
in place, or fuel leak could occur,
leading to catching fire or explosion.
● Check fuel system regularly for
leakage.
6
● Contact authorized dealer for fuel
system services. Services by ■ Fuel filter (for fuel tank)
unqualified person could lead to Remove the fuel pickup elbow of the 7
engine damage.
fuel tank by turning it counterclockwise
and clean the fuel filter.
■ Fuel filter (for engine)
8
① Check in the cup for water and ■ Fuel tank
foreign matter. Water or dirt in the fuel tank will cause
engine performance problems.
9
Check and clean the tank at specified
Body
Arrow to indicate
times or after the outboard motor has 10
fuel flow direction been stored for a long period of time
O-ring (over three months).
Filter Fuel 11
pick up
elbow
O-ring
12
Cup
Filter
13
TOHATSU_25B-30B_E.indd 57 11/02/15 11:41

Replacing gear oil

until oil flows out of the upper plug
! WARNING hole.
1 ● Be sure that outboard motor is

secured to transom or service stand,
or accidental drop or fall of outboard
2 motor could lead to severe personal
injury.
● Be sure to lock outboard motor if
3 it is tilted up, or accidental fall of

personal injury.
● Do not go under outboard motor
4 tilted up and locked, or accidental
severe personal injury. ③ Install the upper oil plug, and then
5 remove oil tube nozzle and install
① Remove the oil plugs (upper and the lower oil plug.
lower), and completely drain the
6 gear oil into a pan.
9
Notes
10
② Insert the oil tube nozzle into the If water in the oil, giving it a milky
lower oil plug hole, and fill with colored appearance. Contact your
dealer.
11 gear oil by squeezing the oil tube
12
! CAUTION Notes
Do not reuse oil plug gasket. Always Use genuine gear oil or the
use new gasket and tighten oil plug recommended one (API GL-5: SAE
13 properly to prevent entry of water into
lower unit.
#80 to #90).
Required volume: approx. 280 ml.
14
TOHATSU_25B-30B_E.indd 58 11/02/15 11:41

3. Off-season storage
⑥ Change the gear oil in the gear
Before you put your outboard motor case.
in storage, it is a good opportunity to
have it serviced and prepared by your
⑦ Apply grease to the propeller shaft.
⑧ Apply grease to all sliding parts,
1
dealer. joints, nuts, and bolts.
⑨ Stand the outboard motor up 2
! CAUTION vertically in a dry place.
Before servicing the motor for storage:

● Remove the battery cables. ! WARNING 3
● Remove the spark plug caps from the
Be sure to use cloth to remove fuel
spark plugs.
4
remaining in the cowl and dispose of it
● Do not run the motor out of the water.
in accordance with local fire prevention
and environment protection regulations.
■ Engine
① Wash the engine exterior and 5
flush the cooling water system ■ Battery
thoroughly with fresh water. Drain ① Disconnect the battery cables.
the water completely. ② Wipe off any chemical deposits, 6
Wipe off any surface water with an dirt, or grease.
oily rag. ③ A p p l y g re a s e t o t h e b a t t e r y
② Use a dry cloth to completely terminals. 7
wipe off water and salt from the ④ Charge the battery completely
electrical components. before storing it for the winter.
③ Drain all fuel from the fuel hoses, ⑤ Recharge the battery once a month
8
fuel pump, and vapor separator, to prevent it from discharging and
and clean these parts.
Keep in mind that if gasoline is
the electrolyte from deteriorating.
⑥ Store the battery in a dry place.
9
kept in the vapor separator for a
long time, gum and varnish will ■ Electric Starter Motor 10
develop, causing the float valve to Coat the internal pinion gears and the
stick, restricting the fuel flow. shaft of the electric starter motor with
④ Remove the spark plugs and grease. 11
spray storage oil (available from Do not put grease on the teeth of the
an authorized dealer) into the starter pinion or flywheel or increased
combustion chamber through wear or damage will occur. 12
the spark plug holes while slowly
turning the motor over using the
recoil starter. 13
⑤ Change the engine oil.
TOHATSU_25B-30B_E.indd 59 11/02/15 11:41

4. Pre-season check 5. Motor submerged in water
① Check that the shift and throttle After taking your outboard motor out
1 function properly.
(Be sure to turn the propeller shaft
of the water, immediately take it to
your dealer.
when checking the shift function The following are the emergency
2 or else the shift linkage may be
damaged.)
measures to be taken for a
submerged outboard motor, if you
can not take it your dealer right away.
3 Notes ① Wash the outboard motor with fresh
The following steps must be taken
water to remove salt or dirt.
when first using the engine after ② Remove the engine oil drain screw
4 winter storage. and completely drain water and oil
① Fill fuel tank completely. from the engine.
② Warm up the engine for 3 minutes ③ Remove the spark plugs, and
5 in the "NEUTRAL" position.
③ Run the engine for 5 minutes at the
completely drain the water from
slowest speed. the engine by pulling the recoil
④ Run the engine for 10 minutes at starter several times.
6 half speed. Replace oil filter and oil to the
In Steps ② and ③ above, the oil correct level.
used for storage inside the engine
The oil and filter may need to be
7 will be flushed out to assure optimum
performance. changed again after running a
short period to get all moisture
② Check the electrolyte level, and completely out of the crankcase.
8 measure the voltage and specific ④ Inject a sufficient amount of engine
gravity of the battery. oil through the spark plug holes.
9 Specific Terminal Charge

Pull the recoil starter several times
to circulate the oil throughout the
Gravity at 20 °C Voltage (V) Condition
outboard motor.
10
Fully
1.120 10.5
discharged
1.160 11.1 1/4 charged

! CAUTION
11 1.210 11.7 1/2 charged Do not attempt to start submerged
outboard motor immediately after it is
1.250 12.0 3/4 charged recovered, or engine could be severely
damaged.
12 1.280 13.2 Fully charged
③ Check that the battery is secure

13 and the battery cables are properly
installed.
14
TOHATSU_25B-30B_E.indd 60 11/02/15 11:41

6. Cold weather precautions 7. Checking after striking underwater object
If you moor your boat in cold weather Striking the sea bottom or an
at temperatures below 0˚C (32˚F),
there is the danger of water freezing
underwater object may severely
d a m a g e t h e o u t b o a r d m o t o r.
1
in the cooling water pump, which may Immediately bring the outboard motor
damage the pump, impeller, etc. To to the dealer and ask for the following 2
avoid this problem, submerge the checks.
lower half of the outboard motor into
the water. ① Looseness or damage of power 3
unit installation bolts, gear case
and extension case bolts, propeller
shaft housing bolts, propeller or 4
propeller shaft upper and lower
mount rubber bolts, and/or mount
bracket bolts. 5
Ask an authorized dealer to tighten
any loose bolts and nuts, and to 6
replace damaged parts.
② Damage to mount rubber, the tilt 7

stopper, thrust rod, gears and
clutch, and/or propeller.
8
Ask an authorized dealer to replace
damaged or defective parts.
9
10
11
12
13
TOHATSU_25B-30B_E.indd 61 11/02/15 11:41

62
TROUBLESHOOTING
If you encounter a problem, consult the check list below to determine the cause
and to take the proper action.
An authorized dealer will always be happy to provide any assistance and
1 information.
Low engine speed/Poor boat speed
2
Battery will not hold charge
Starter motor will not crank
Warning lamp "Flash" *2

Power T & T inoperative
Difficult to start engine
Engine runs erratically
Warning lamp "ON" *1
3 Possible cause
5 ● Empty fuel tank
● ● Incorrect connection of fuel system
6 ● ● Air entering fuel line
● ● Deformed or damaged fuel hose

FUEL SYSTEM
7 ● Closed air vent on fuel tank
● ● Clogged fuel filter or fuel pump
8 ● Use of improper engine oil
● ● ● Use of improper gasoline
● Not enough fuel supply by primer

9 Water temp or MAP sensor out of range or improper or
● ●
loose wiring connection.
10 ● ● Spark plug other than specified

E/SYSTEM
● ● ● Dirt, soot, etc. on spark plug
11 ● ● No Spark or weak spark
12
13
14
TOHATSU_25B-30B_E.indd 62 11/02/15 11:41

1
2

3
Possible cause
4
● Short circuit of engine stop switch
5
● Rectifier failure
● Lack of stop switch lock plate
● ● ● Disconnection of wire or loose ground connection

6
ELECTRICAL SYSTEM
● ● Blown 20 Amp fuse in the starting circuit
● ● Not shifted into neutral position 7

● ● ● Weak battery or battery connections are loose or corroded
● ● Ignition key switch failure 8

● Wiring or electrical connection faulty
● Starter motor or starter solenoid failure

9
● Power trim & tilt switch defective, Solenoid is defective
● ● ● ●
10
Wrong wiring, disconnection, poor connection
11
12
13
TOHATSU_25B-30B_E.indd 63 11/02/15 11:41

64 TROUBLESHOOTING
1
2


Possible cause
3
5
● ● Low compression
COMPRESSION &
OIL SYSTEM
● Carbon deposits in the combustion chamber
● Incorrect valve clearance

6 Low oil pressure/level, oil pump failure, Clogged oil filter
● ●
(Pressure switch ON)
7 ● Insufficient throttle aperture
● ● Insufficient cooling water flow, clogged or defective pump
8
● ● Faulty thermostat
● ● Cavitations or ventilation
OTHERS
● ● ● Incorrect propeller selection

9 ● ● Damaged or bent propeller
● Improper thrust rod position
10 ● ● Unbalanced load on boat
● Transom too high or too low
11 ● A great deal of air is contained inside pump
*1: Horn also sounds continuously.

*2: Horn also sounds intermittently.
12
13
14
TOHATSU_25B-30B_E.indd 64 11/02/15 11:41

65
TOOL KIT AND SPARE PARTS

The following a list of the tools and spare parts provided with the motor.
Items Quantity Remark
Tool bag
Pliers
1
1 1
Socket wrench 1 10 × 13 mm
Service tools Socket wrench 1 16 mm
Socket wrench handle
Screwdrivers
1
1 Cross-and straight-point
2
Screwdriver handle 1
Spare parts
Starter rope
Spark plug
1
2
1,000 mm
NGK DCPR6E
3
Split pin 1
Fuel tank
Primer bulb
1
1 set
25L
4
Remote control box 1 set
　 for EP and EPT
Drag link 1
5
Parts Packaged Bracket fixing
with Engine Bolt 2 8 mm
Nut
Washer
2
4
8 mm
8 mm
for MF/EF and EP
6
Bolt 4 12 mm
Nut 4 12 mm for MFG/EFG/EFT
Washer A, B 4 each A (large)
B (small)
and EPT
7
10
11
12
13
TOHATSU_25B-30B_E.indd 65 11/02/15 11:41

66
OPTIONAL ACCESSORIES
1 Flushing attachment
2 Genuine engine oil (450ml)
3 Drive cleaner
Trim Meter
7 Genuine gear oil (500ml) Trim Meter Kit
9
Touch-up paint (300ml)
10
11
12
13
14
TOHATSU_25B-30B_E.indd 66 11/02/15 11:41

67
PROPELLER TABLE
Use a genuine propeller.
A propeller must be selected so that the engine rpm measured at wide open
throttle while cruising is within the recommended range.
25: 5,000 to 6,000 rpm

1
30: 5,250 to 6,250 rpm
2
Propeller Size (Diameter x pitch)
Propeller Mark
inch mm
3
Light boats
14 9.9 × 14.2 252 × 360
4
DS13 9.6 × 13 244 × 330
5
DS12 9.8 × 12 249 × 305
6
DS11 9.8 × 11 249 × 279
DS10 9.72 × 10 247 × 254

7
DS9 9.72 × 9 247 × 229 8
Heavy boats
8 10.2 × 8.3 260 × 210 9
10
11
12
13
TOHATSU_25B-30B_E.indd 67 11/02/15 11:41

MEMO
TOHATSU_25B-30B_E.indd 68 11/02/15 11:41

MEMO
TOHATSU_25B-30B_E.indd 69 11/02/15 11:41

MEMO
TOHATSU_25B-30B_E.indd 70 11/02/15 11:41

! 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 © 2009 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.

OWNER’S
MANUAL
OWNER’S MANUAL
MFS 25B
MFS 25B TOHATSU CORPORATION
30B
30B
Address : 5-4, 3-chome, Azusawa, Itabashi-ku,
TOKYO, 174-0051 JAPAN
Phone : TOKYO (03)3966-3117
FAX : TOKYO (03)3966-2951 OB No.003-11080-4
URL : www.tohatsu.co.jp
003-11080-4 1012NB
Printed in Japan

Tohatsu - MFS25B Owner's Manual 2009

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TOHATSU_25B_30B_E_cover.indd 1 11/02/15 11:41

TOHATSU_25B_30B_E_cover.indd 2 11/02/15 11:41

TOHATSU_25B-30B_E.indd 1 11/02/15 11:40

To You, Our Customer

TOHATSU_25B-30B_E.indd 2 11/02/15 11:40

TOHATSU_25B-30B_E.indd 3 11/02/15 11:40

GENERAL SAFETY INFORMATION

6.REMOVING AND CARRYING THE MOTOR 6

9.INSPECTION AND MAINTENANCE 9

11.TOOL KIT AND SPARE PARTS 11

TOHATSU_25B-30B_E.indd 7 11/02/15 11:40

EMERGENCY STOP SWITCH

TOHATSU_25B-30B_E.indd 8 11/02/15 11:40

SERVICING, REPLACEMENT PARTS & LUBRICANTS

TOHATSU_25B-30B_E.indd 9 11/02/15 11:40

MODEL 25B MF 25B EF 25B EP

1 Item 30B MF 30B EF 30B EP

Overall Width mm (in) 391 (15.4) 367 (14.4)

Transom Height S·L mm (in) 404 (15.9) · 552 (21.7)

4 Output kW (Hp) 25B : 18.4 (25) 30B : 22.1 (30)

Engine Type 4-Stroke EFI

Bore × Stroke mm (in) 61 × 60 (2.40 × 2.36)

7 Piston Displacement mL (Cu in) 526 (32.09)

Exhaust System Through hub exhaust

8 Cooling System Water cooling

Engine Lubrication Trochoid pump

Ignition System Flywheel Magneto C.D. ignition

Spark Plug NGK DCPR6E

NMMA FC-W certified 10W-30 or

Genuine Gear Oil or API GL5,

Fuel Tank Capacity L (US gal) 25 (6.60)

Emission Control System ECU

＊ : with manual ※ Specifications subject to change without notice.

TOHATSU_25B-30B_E.indd 10 11/02/15 11:40

MODEL 25B MFG 25B EFG

Overall Width mm (in) 391 (15.4)

Overall Height S·L mm (in) 1,187 (46.7) · 1,335 (52.6)

S Kg (lb) 78 (172) 81 (179) 3

Output 25B : 18.4 (25) 30B : 22.1 (30) 4

Idle Speed rpm 850 + or - 30

Piston Displacement mL (Cu in) 526 (32.09) 7

Cooling System Water cooling

Startring System Manual Electric starter motor*

Spark Plug NGK DCPR6E

Gear Reduction Ratio 1.92 (12 : 23)

＊ : with manual ※ Specifications subject to change without notice.

TOHATSU_25B-30B_E.indd 11 11/02/15 11:40

MODEL 25B EFT 25B EPT

Overall Width mm (in) 391 (15.4) 367 (14.4)

Transom Height S·L mm (in) 404 (15.9) · 552 (21.7)

3 S Kg (lb) 82.5 (182) 81 (179)

4 Output 25B : 18.4 (25) 30B : 22.1 (30)

Engine Type 4-Stroke EFI

Bore × Stroke mm (in) 61 × 60 (2.40 × 2.36)

7 Piston Displacement mL (Cu in) 526 (32.09)

Exhaust System Through hub exhaust

8 Cooling System Water cooling

Engine Lubrication Trochoid pump

Ignition System Flywheel Magneto C.D. ignition

Spark Plug NGK DCPR6E

NMMA FC-W certified 10W-30 or

Genuine Gear Oil or API GL5,

Continuous (2) ON (2) ON (2) Low oil pressure (1) ② 3