Tohatsu M40D2 Troubleshooting
| Engine Model: Tohatsu M40D2 |
| Engine Type: 2-stroke 3-cylinder gasoline outboard engine |
| Total Displacement: 42.5 cu.in (697 cc) |
| Rated Engine Power: 40 Hp (29.4 kW) at 5500 rpm |
| Fuel System: Carburetor |
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| Engine starts up hard or doesn't start |
Empty fuel tank - Add gasoline.
Wrong fuel grade - Change fuel.
Air in the fuel lines - Bleed the fuel lines.
Spark plug wiring connection is damaged - Inspect the spark plug wire connection, replace or repair.
Spark plug is faulty - Spark plug need to be replaced.
Fuel filter is plugged - Replace fuel filter.
Carburetor is clogged - Clean the carburetor.
Fuel lines clogging - Clean fuel lines.
Fuel tank air vent restricted or closed - Open or service air vent.
Lack of fuel pump pressure - Install new fuel pump or rebuild it.
Reed valve is faulty or worn - Replace reed valve.
| Engine stalls after starting |
Damaged spark plug - Change spark plug.
Carburetor is defective or dirty - Repair or clean carburetor.
Ignition coil is not working - Change ignition coil as required.
Closed or clogged fuel tank air vent - Fuel tank air vent need to be opened or cleaned.
Lack of fuel pump pressure - Install new fuel pump or rebuild it.
Ignition system is defective - Check ignition system and replace faulty parts.
Dirty or defective fuel pump - Service or replace fuel pump.
Incorrect carburetor adjustment - Adjust carburetor idle mixture screw.
Fuel lines clogging - Fuel lines must be clean.
Fuel tank air vent closed or restricted - Open or clean air vent.
Fuel filter is dirty - Fuel filter needs changing.
Gaskets are worn - Replace gaskets.
Engine is overloaded - Load reducing required.
Carburetor mixture is too lean - Adjust carburetor correctly.
Incorrect ignition timing - Set the ignition timing correctly.
Defective thermostat - Change thermostat as required.
Water pump failure - Water pump need to be replaced.
Incorrect propeller selection - Replace propeller.
Damaged or bent propeller - Replace propeller.
Outboard motor is mounted too high or too low - Mount the motor as required.
Low octane gasoline - Use proper gasoline.
Engine overload - Load reducing required.
Low idle speed setting is incorrect - Adjust the low idle speed.
Fuel pump is damaged or dirty - Check fuel pump and change if required.
Main bearings or crankshaft are worn out - Change or repair worn components.
Worn cylinder bore or piston rings - Change faulty parts.
Incorrectly adjusted or clogged carburetor - Service or properly adjust carburetor.
Dirty or defective fuel pump - Service or change fuel pump.
Ignition system problems - Check ignition and replace faulty components.
Gaskets are worn - Change gaskets.
Damaged powerhead components - Replace defective parts.
Propeller selection improperly - Replace propeller.
Damaged or bent propeller - Have propeller repaired or replaced.
Outboard motor mounting height is set incorrectly - Check the outboard motor mounting height.
Incorrect trim angle - Adjust trim angle.
| Engine uses too much fuel |
Improper carburetor main jet adjustment - Adjust it correctly.
Faulty or loose spark plug - Tighten or change the spark plug.
Rings, sleeve, or piston are damaged - Replace defective parts.
| Motor vibrates excessively |
Damaged or bent propeller - Have propeller repaired or replaced.
Propeller shaft damaged - Have propeller shaft replaced.
Weeds wraped around propeller - Remove weeds from propeller.
Motor mounting bolt is loose - Tighten bolt.
Steering pivot is faulty or loose Tighten or replace.
Low battery power - Low battery charging, charge as required.
Battery discharges quickly - Service or change the battery.
Corroded battery terminals or disconnected wires - Connect wires correctly or change terminals.
Starter motor failure - Starter should be replaced.
| Trim motor is running but trim system cannot move up or down |
Insufficient oil - Checking oil level and add if necessary.
Pump assembly faulty - Inspect pump and change as required.
Manual shut-off valve leaks - Valve need to be closed or changed.
Pump driveshaft or motor damaged - Change worn component.
| Trim cannot be fully up or down |
Damaged pump assembly - Change pump.
Tilt ram piston ball is displaced - Service or repair.
Worn tilt ram piston O-ring - Replace O-ring.
Insufficient oil - Checking oil level and add if necessary.
Lower check valve is not properly secured in port side trim ram - Secure valve properly.
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