background image

4-3

E

When transporting or storing the out-
board motor while removed from a boat,
fold the tiller handle and lean the motor
on the tiller handle to keep in a horizontal
position.

NOTE:

Place a towel or the like under the out-
board motor to protect it from damage.

c

C

Keep the power unit higher than the pro-
peller at all times. Otherwise, cooling
water can run into the cylinder, which
could result in damage.

102013

EMU01785

STORING OUTBOARD MOTOR

25, 25-3

When storing your outboard motor for
prolonged periods of time (2 months or
longer), several important procedures
must be performed to prevent excessive
damage. It is advisable to have your out-
board motor serviced by an authorized
Yamaha dealer prior to storage. However,
the following procedures can be per-
formed by the owner with a minimum of
tools.

c

C

8

Do not place the outboard motor on its
side before the cooling water has
drained from it completely, otherwise
water may enter the cylinder through
the exhaust port and cause engine
trouble.

8

Store the outboard motor in a dry,
well-ventilated place, not in direct sun-
light.

 6L2-9-1K-4  2/25/03 15:51  Page 4

Summary of Contents for 25C

Page 1: ...25C OWNER S MANUAL U S A Edition LIT 18626 05 42 ...

Page 2: ......

Page 3: ...s special precautions that must be taken to avoid damage to the outboard motor NOTE A NOTE provides key information to make procedures easier or clearer Yamaha continually seeks advance ments in product design and quality Therefore while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your machine and this manual ...

Page 4: ...GENERAL INFORMATION BASIC COMPONENTS OPERATION MAINTENANCE TROUBLE RECOVERY INDEX EMA20010 CONTENTS READ THIS OWNER S MANUAL CAREFULLY BEFORE OPERATING YOUR OUTBOARD MOTOR 1 2 3 4 5 6 E ...

Page 5: ... NUMBERS RECORD 1 1 Outboard motor serial number 1 1 EMISSION CONTROL INFORMATION 1 2 SAFETY INFORMATION 1 3 IMPORTANT LABELS 1 5 BASIC BOATING RULES 1 6 FUELING INSTRUCTIONS 1 10 Gasoline 1 11 Engine oil 1 11 PROPELLER SELECTION 1 12 START IN GEAR PROTECTION 1 13 E ...

Page 6: ...he label attached to the port side of the clamp bracket Record your outboard motor serial num ber in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your out board motor is stolen 1 Outboard motor serial number 1 401012 YAMAHA MOTOR CO LTD MADE IN JAPAN PAYS D ORIGINE JAPON ...

Page 7: ... bottom cowl ing 1 Emission control information label Existing Technology N A Manufactured date label This label is attached to the clamp bracket or the swivel bracket 2 Manufactured date label EMISSION CONTROL INFORMATION ENGINE FAMILY THIS ENGINE CONFORMS TO 2001 U S EPA REGULATIONS FOR MARINE SI ENGINES REFER TO THE OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS FELs SPARK PLUG DI...

Page 8: ... obstacles and other traffic 8 Always watch carefully for swimmers during the engine operation 8 Stay away from swimming areas EMU00917 SAFETY INFORMATION 8 Before mounting or operating the out board motor read this entire manual Reading it should give you an under standing of the motor and its operation 8 Before operating the boat read any owner s or operator s manuals supplied with it and all la...

Page 9: ...ny organizations including the following United States Coast Guard Consumer Affairs Staff G BC Office of Boating Public and Consumer Affairs U S Coast Guard Headquarters Washington D C 20593 0001 Boating Safety Hotline 1 800 368 5647 National Marine Manufacturers Association NMMA 401 N Michigan Ave Chicago Il 60611 Marine Retailers Association of America 155 N Michigan Ave Chicago Il 60601 ...

Page 10: ...unless the shift control is in neutral position 6E0 83627 41 WARNING Be sure shift control is in neutral before starting engine except 2HP Do not touch or remove electrical parts when starting or during operation Keep hands hair and clothes away from flywheel and other rotating parts while engine is running 6A1 83625 41 25 LOCATION 202061 q w 25 3 30 ...

Page 11: ...r dened vessel These rules determine which vessel has the right of way and what each vessel should do Stand on vessel The vessel with the right of way has the duty to continue its course and speed except to avoid an immediate collision When you maintain your direction and speed the other vessel will be able to determine how best to avoid you Give way vessel The vessel which does not have the right...

Page 12: ...ssel head on and are close enough to run the risk of collision neither of you has the right of way Both of you should alter course to avoid an accident You should keep the other vessel on your port left side This rule doesn t apply if both of you will clear one another if you continue on your set course and speed Crossing When two power driven vessels are crossing each other s path close enough to...

Page 13: ...nnot howev er impede the passage of other vessels in narrow channels Sailing vessel right of way Sailing vessels should normally be given the right of way The exceptions to this are 1 When the sailing vessel is overtaking the power driven vessel the power driven vessel has the right of way 2 Sailing vessels should keep clear of any fishing vessel 3 In a narrow channel a sailing vessel should not h...

Page 14: ...L M A I N C H A N N E L old new 2 2 2 A L L Odd number increasing toward head of naviga MAIN CHANNEL BUOYS 1 3 5 7 tion Leave to port left proceeding upstream LIGHTED BUOY Port Hand White Light Green Light old new old new old new LIGHTED BUOY Starboard Hand 2 4 6 Even number increasing toward head of naviga tion Leave to starboard right proceeding up stream White Light Red Light A LIGHTED SAFE WAT...

Page 15: ...tely with dry rags 8 Do not overfill the fuel tank 8 Tighten the filler cap securely after refueling 8 If you should swallow some gasoline inhale a lot of gasoline vapor or get gasoline in your eyes get immediate medical attention 8 If any gasoline spills onto your skin immediately wash with soap and water Change clothing if gasoline spills on it 8 Touch the fuel nozzle to the filler open ing or f...

Page 16: ...e used if ethanol content does not exceed 10 and the fuel meets minimum octane ratings Gasohol containing methanol is not recommended by Yama ha because it can cause fuel system dam age or engine performance problems EMU01804 GASOLINE If knocking or pinging occurs use a differ ent brand of gasoline or premium unlead ed fuel Recommended gasoline Regular unleaded gasoline with a minimum octane ratin...

Page 17: ...dverse effect on the engine Yamaha outboard motors are fitted with propellers chosen to perform well over a range of applications but there may be uses where a propeller with a different pitch would be more appropriate For a greater operating load a smaller pitch propeller is more suitable as it enables the correct engine speed to be main tained Conversely a larger pitch pro peller is more suitabl...

Page 18: ...s rpm should be within the upper half of the full throttle operating range as listed in SPECIFICA TIONS on page 4 1 Select a propeller which fulfills this requirement If operating under conditions which allow the engine s rpm to rise above the maxi mum recommended range such as light boat loads reduce the throttle setting to maintain the rpm in the proper operating range 1 Propeller diameter in in...

Page 19: ...p button 2 5 Tiller handle 2 5 Choke knob 2 6 Recoil starter handle 2 6 Steering friction adjusting screw 2 7 Trim tab 2 8 Trim angle adjusting rod 2 8 Shallow water lever 2 9 Tilt lock mechanism 2 9 Tilt support bar 2 10 Tilt support lever 2 10 Top cowling lock lever 2 10 WARNING SYSTEM 2 11 Overheat warning 2 11 Oil level warning oil filter clogging warning 2 12 1 2 3 4 5 6 E ...

Page 20: ...rol grip Tiller handle 6 Engine stop button Engine stop lanyard switch 7 Transom clamp handle 8 Tilt lock lever 9 Cooling water inlet 0 Propeller q Trim tab Anode w Anti cavitation plate e Trim angle adjusting rod r Rope attachment t Shallow water lever y Fuel tank May not be exactly as shown also may not be included as standard equipment on all models 25 ...

Page 21: ...mp handle 7 Trim angle adjusting rod 8 Cooling water inlet 9 Propeller 0 Anti cavitation plate q Trim tab w Clamp bracket e Tilt support lever r Rope attachment t Top cowling y Choke knob u Engine stop button engine stop lanyard switch i Warning indicator o Remote control box p Fuel tank May not be exactly as shown also may not be included as standard equipment on all models 25 3 30 ...

Page 22: ...se Fuel meter This meter is on the fuel tank cap It shows current fuel quantity in the fuel tank approximately Fuel tank cap This cap is for filling fuel To remove it turn it counterclockwise Air Vent screw This screw is on the fuel tank cap To loosen it turn it counterclockwise EMC25010 GEAR SHIFT LEVER for Tiller control model Turning the gear shift lever towards you engages the clutch with the ...

Page 23: ...ower 1 Lock plate 2 Lanyard w 8 Attach the engine stop switch lanyard to a secure place on your clothing your arm or leg while operating 8 Do not attach the lanyard to clothing that could tear loose Do not route the lanyard in such a way that it could become entangled preventing it from functioning 8 Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss...

Page 24: ...ottle indicator 3 Throttle friction adjusting knob screw E 503022 q 503021 e q w 503032 EMU00067 Throttle Indicator The fuel consumption curve on the throt tle indicator shows the relative amount of fuel consumed for each throttle position Choose the setting that offers the best performance and fuel economy for the desired operation 1 Throttle indicator 3 25 25 3 30 EMU00065 Throttle Control Grip ...

Page 25: ...ob If there is too much resistance it may be difficult to move the throttle grip which could result in an accident Resistance Knob Screw Increase Turn clockwise Decrease Turn counterclockwise EMC42010 CHOKE KNOB Pulling out this knob setting it to ON supplies a rich mixture required to start the engine NOTE The choke knob for Remote control model has the same function as the choke switch on the re...

Page 26: ...s adjustable for operator preference An adjusting screw bolt is located on the swivel brack et EMD00310 Adjustment w Do not overtighten the friction screw bolt If there is too much resistance it may be difficult to steer which could result in an accident Resistance Screw bolt Increased Turn clockwise Decreased Turn counterclockwise 408015 ...

Page 27: ...sting the trim tab 1 Trim tab 2 Bolt 3 Cap If equipped cC The trim tab also serves as an anode to protect the engine from electrochemical corrosion Never paint the trim tab as it will become ineffective as an anode 603011 w q A B 001769 25 404015 25 3 30 Boat tends The fin of trim tab to veer To the left Turn to the left port side A in the figure To the right Turn to the right starboard B in the f...

Page 28: ...30 Pushing this lever down will tilt the motor up partially to provide more clearance when operating in shallow water EMD44010 TILT LOCK MECHANISM for Manual tilt model The tilt lock mechanism is used to pre vent reverse thrust from the propeller lift ing the outboard motor when reversing To lock it set the tilt lock lever in the up position To release it push the tilt lock lever down 1 Tilt lock ...

Page 29: ... sure it fits properly in the rub ber seal Then lock the cowling again by moving the lever upward 403023 q 403024 25 25 3 30 EMD60210 TILT SUPPORT LEVER 25 3 30 To keep the outboard motor in the tilted up position lock the tilt support lever to the swivel bracket EMU00156 TILT SUPPORT BAR 25 The tilt support bar 1 keeps the outboard motor in the tilted up position ...

Page 30: ... This engine has an overheat warning device If the engine temperature rises too high the warning device will activate 2 Included N A If the warning system has been activated stop the engine and check the water inlet for clogging Activation of warning device The engine speed will automatically decrease to about 2 000 r min The overheat warning indicator will come on The buzzer will sound Tiller Rem...

Page 31: ...nd check for the cause NOTE The warning for oil filter clogging is simi lar to the warnings for low oil level and overheating For easy troubleshooting it is advisable to check for engine overheat ing first then oil level and finally oil filter clogging 1 Oil filter Warning device activation The engine speed will automatically decrease to about 2 000 r min The oil level warning indicator will come ...

Page 32: ...g indicator lamp Bottom cowling Remarks Engine oil tank OFF No refilling necessary more than 200 cm3 0 21 US qt 0 181 Imp qt Red ON Buzzer sounds in remote control box and engine speed is limited to about 2 000 r min to help conserve oil Check oil filter for clogging Add oil 200 cm3 or less 0 21 US qt 0 181 Imp qt ...

Page 33: ...RE OPERATION CHECKS 3 10 Operation after a long period of storage 3 11 BREAKING IN ENGINE 3 12 STARTING ENGINE 3 14 WARMING UP ENGINE 3 18 SHIFTING 3 19 Forward 3 19 Reverse 3 20 STOPPING ENGINE 3 21 TRIMMING OUTBOARD MOTOR 3 22 Adjusting trim angle 3 23 CRUISING IN SHALLOW WATER 3 25 TILTING UP DOWN 3 27 CRUISING IN OTHER CONDITIONS 3 30 Cruising in salt water 3 30 Cruising in turbid water 3 30 1...

Page 34: ...rne water spray while the boat is cruising Severe engine damage may result if the motor is operat ed continuously in the presence of air borne water spray NOTE During water testing check the buoyancy of the boat at rest with its maximum load Check that the static water level on the exhaust housing is low enough to pre vent water entry into the powerhead when water rises due to waves when the outbo...

Page 35: ...he specific boat motor com bination 8 Your dealer or other person experi enced in proper rigging should mount the motor If you are mounting the motor yourself you should be trained by an experienced person permanent mounted type 8 Your dealer or other person experi enced in proper outboard motor mounting should show you how to mount your motor portable type Mount the outboard motor on the center l...

Page 36: ...eight is too high cavitation tends to occur thus reducing the propulsion and if the pro peller tips cut the air the engine speed will rise abnormally and cause the engine to overheat If the mounting height is too low the water resistance will increase and thereby reduce engine efficiency Mount the engine so that the anti cavita tion plate is between the bottom of the boat and a level 25 mm 1 in be...

Page 37: ...oose clamp screws could allow the motor to move on the transom or fall off the transom This could cause loss of control and serious injury Make sure the transom screws are tightened securely Occasionally check the screws for tight ness during operation 2 An engine restraint cable or chain should be used Attach one end to the engine restraint cable attachment point and the other to a secure mountin...

Page 38: ...n and resulting emissions regulations One of the most obvious changes has been the elimination of lead from most fuels As gasoline has changed the amount of additives such as aromatics and oxy genates has increased These additives are important for the engines in passen ger cars but they can have detrimental effects in marine engines particularly 2 cycle outboards because of increased deposits in ...

Page 39: ... See Chapter 4 Specifications EMU01800 FILLING OIL This engine uses the oil injection system which provides superior lubrication by ensuring the proper oil ratio for all operat ing conditions No fuel premixing is need ed except during break in Simply pour gasoline into the fuel tank and oil into the oil tank Convenient indicator segments indicate the status of the oil supply For details on reading...

Page 40: ... cowling 2 Open the oil tank filler cap by pulling the tab 3 Slowly fill the engine oil into the engine oil tank 4 After filling replace the cap securely 5 Replace the top cowling securely 1 Engine oil tank 2 Oil tank filler cap 203012 q w 30 ...

Page 41: ... oil other than the des ignated type 8 Use a thoroughly blended fuel oil mix ture 8 If the mixture is not thoroughly blend ed or if the mixing ratio is incorrect the following problems could occur Low oil ratio Lack of oil could cause major engine trouble such as piston seizure High oil ratio Too much oil could cause fouled spark plugs smoky exhaust and heavy carbon deposits Engine oil Gasoline Pe...

Page 42: ...l 0 22 Imp gal 2 6 Imp gal 3 1 Imp gal 5 3 Imp gal Mixing ratio 100 1 Gasoline Petrol Engine oil 0 01 L 0 12 L 0 14 L 0 24 L 0 01 US qt 0 13 US qt 0 15 US qt 0 25 US qt 0 01 Imp qt 0 11 Imp qt 0 12 Imp qt 0 21 Imp qt 1 L 12 L 14 L 24 L 0 26 US gal 3 2 US gal 3 7 US gal 6 3 US gal 0 22 Imp gal 2 6 Imp gal 3 1 Imp gal 5 3 Imp gal NOTE If using a permanently installed tank pour the oil gradually as t...

Page 43: ... or gasoline fumes 8 Check fuel line connections to be sure they are tight 8 Be sure the fuel tank is positioned on a secure flat surface and that the fuel hose is not twisted or flattened or likely to contact sharp objects EMU00207 Oil 8 Check to be sure you have plenty of oil for your trip EMU00209 Controls 8 Check throttle shift and steering for proper operation before starting the engine 8 The...

Page 44: ...ne Leave it idling w 8 Do not touch or remove electrical parts when starting or during operation 8 Keep hands hair and clothes away from the flywheel and other rotating parts while the engine is running 3 Watch for oil flowing through the oil feed pipes After any air in the oil lines has been expelled the oil injec tion system should supply oil normal ly If no oil is flowing after 10 minutes of id...

Page 45: ...ddition to oil in the oil injection system For oil injection system models Gasoline to engine oil premix ratio during break in 50 1 Break in time 10 hours For premix models Gasoline to engine oil premix ratio during break in 25 1 For details on mixing fuel and oil see Gasoline and oil mixing in this chapter Mixing ratio 50 1 Gasoline Petrol Engine oil 0 02 L 0 24 L 0 28 L 0 48 L 0 02 US qt 0 25 US...

Page 46: ...ngine speed to three quarter throttle approximately 4 000 r min Vary engine speed occasional ly Run at full throttle for one minute then allow about 10 minutes of opera tion at three quarter throttle or less to let the engine cool 4 Third through tenth hours Avoid operating at full throttle for more than 5 minutes at a time Let the engine cool between full throttle runs Vary engine speed occasiona...

Page 47: ...efrain from smoking and keep away from open flames and sparks while loosening the air vent screw 8 This product emits exhaust gases which contain carbon monoxide a col orless odorless gas which may cause brain damage or death when inhaled Symptoms include nausea dizziness and drowsiness Keep cockpit and cabin areas well ventilated Avoid blocking exhaust outlets Oil injection system models 5 After ...

Page 48: ...oint on the motor firmly connect the fuel line to the joint Then firmly connect the other end of the fuel line to the joint on the fuel tank NOTE During engine operation place the tank horizontally or fuel cannot be drawn into the engine EMU01497 PROCEDURE FOR TILLER CONTROL MODEL 4 Place the gear shift lever in the neu tral position NOTE The start in gear protection device pre vents the engine fr...

Page 49: ... Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss of most steering control Also without engine power the boat could slow rapidly This could cause people and objects in the boat to be thrown forward 6 Place the throttle control grip in the START position 407016 308013 25 25 3 30 503022 305022 305023 25 25 3 30 EMU00240 Manual Start Model 7 Pull out ...

Page 50: ...nce Then give a strong pull straight out to crank and start the engine Repeat it if neces sary 9 After the engine starts return the starter handle slowly to the original position before releasing it 209015 503012 10 Return the throttle to the fully closed position ...

Page 51: ...cC A continuous flow of water from the pilot hole shows that the water pump is pumping water through the cooling pas sages If water is not flowing out of the pilot hole at all times while the engine is running do not continue to run the engine Overheating and serious damage could occur Stop the engine and check to see if the water inlet on the lower cas ing is blocked If the problem cannot be foun...

Page 52: ...C To change the shifting position from for ward to reverse or vice versa close the throttle first so that the engine idles or runs at low speeds 406013 N F 503012 2 Turn the gear shift lever quickly and firmly from Neutral to Forward EMU00263 FORWARD 1 Place the throttle control grip in the fully closed position ...

Page 53: ...le which could result in loss of control and an accident 406014 N R 503012 402062 402051 25 25 3 30 2 Check that the tilt lock lever for Man ual tilt model is in the locked posi tion 3 Turn the gear shift lever quickly and firmly from Neutral to Reverse 1 Place the throttle control grip in the fully closed position for Tiller control model ...

Page 54: ...p button or turn the main switch to OFF 2 If the fuel joints are provided discon nect the fuel line from the motor after stopping the engine 3 Tighten the air vent screw on the fuel tank cap after stopping the engine if it is equipped 4 Remove the key if the boat will be left unattended NOTE The engine can also be stopped by pulling the lanyard and removing the lock plate from the engine stop lany...

Page 55: ...at engine and propeller Correct trim is also affected by variables such as the load in the boat sea conditions and running speed w Excessive trim for the operating condi tions either trim up or trim down can cause boat instability and can make steering the boat more difficult This increases the possibility of an accident If the boat begins to feel unstable or is hard to steer slow down and or read...

Page 56: ...e bow trim in move the rod toward the transom Make test runs with the trim set to differ ent angles to find the position that works best for your boat and operating condi tions w 8 Stop the engine before adjusting the trim angle 8 Use care to avoid being pinched when removing or installing the rod 8 Use caution when trying a trim position for the first time Increase speed gradu ally and watch for ...

Page 57: ... in the water Performance and economy are decreased because the hull of the boat is pushing the water and there is more air drag Excessive trim out can also cause the propeller to ventilate which reduces performance further and the boat may porpoise hop in the water which could throw the operator and passengers overboard Bow Down When the bow of the boat is down it is easier to accelerate from a s...

Page 58: ...peed when using the shallow water cruising system The tilt lock mecha nism does not work while the shallow water cruising system is being used Hitting an underwater obstacle could cause the engine to lift out of the water resulting in loss of control 8 Use extra care when operating in reverse Too much reverse thrust can cause the engine to lift out of the water increasing the chance of acci dent a...

Page 59: ... plate turns com pletely 3 Pull up the shallow water lever 4 Slightly tilt up the engine The tilt support bar will lock automatically supporting the engine in a partially raised position NOTE If the engine is tilted up completely the tilt lock lever automatically locks The shallow water lever is no longer effective 5 When lowering the engine set the tilt lock lever and shallow water lever to the l...

Page 60: ...an result 8 Do not tilt up the engine by pushing the steering handle as this could break the handle 8 Keep the power unit higher than the propeller at all times Otherwise water can run into the cylinder causing dam age w Be sure all people are clear of the out board motor when adjusting the tilt angle also be careful not to pinch any body parts between the drive unit and engine bracket 105031 4120...

Page 61: ... connection from the motor N 406012 402061 402075 3 Push the tilt lock lever to release 4 Pull up the shallow water lever w Leaking fuel is a fire hazard Disconnect the fuel line if the engine will be tilted for more than a few minutes Otherwise fuel may leak If the fuel connector is provid ed on the motor ...

Page 62: ...G UP 25 3 30 1 Remove the fuel line connection from the motor If the fuel connector is provided on the motor 2 Place the tilt lock lever in Release 3 Hold the rear of the top cowling with one hand tilt the engine up and turn the tilt support lever to the locked position and support the engine 5 Hold the rear of the top cowling with one hand and fully tilt the engine up 6 The tilt support bar turns...

Page 63: ...deposits NOTE Refer to cooling system flushing instruc tions in TRANSPORTING AND STORING OUTBOARD MOTOR CRUISING IN TURBID WATER It is strongly recommended that the optional chromium plated water pump kit be installed if the outboard is to be used in turbid muddy water conditions EMG73210 PROCEDURE FOR TILTING DOWN 25 3 30 1 Return the tilt support lever tilting up the engine slightly 2 Tilt down ...

Page 64: ...E MEMO ...

Page 65: ...k plug 4 9 Checking top cowling 4 10 Checking fuel system 4 11 Inspecting fuel filter 4 12 Inspecting idling speed 4 13 Checking water in engine oil tank 4 14 Checking wiring and connectors 4 15 Exhaust leakage 4 15 Water leakage 4 15 Greasing 4 16 Checking propeller 4 18 Changing gear oil 4 20 Cleaning fuel tank 4 21 Inspecting and replacing anode s 4 22 Checking bolts and nuts 4 23 Motor exterio...

Page 66: ...Control system 8Starting system 8Alternator output V A W 8Starting carburetion system 2 stroke L 2 395 24 1 67 56 2 6 2 2 C D I system B7HS 10 0 9 1 0 0 035 0 039 Tiller control Manual start 12V 80W Choke start system DRIVE UNIT 8Gear positions Gear ratio 8Trim tilt system 8Propeller mark Forward Neutral Reverse 2 08 27 13 Manual F FUEL AND OIL TIGHTENING TORQUE 8Fuel Fuel tank capacity L US gal I...

Page 67: ...ot use the tilt support lever knob when trailering the boat The outboard motor could shake loose from the tilt support and fall If the motor can not be trailered in the down position use an additional support device to secure it in the up position w 8 Never get under the lower unit while it is tilted even if a motor support bar is used Severe injury could occur if the outboard accidentally falls 8...

Page 68: ...MOTOR 25 25 3 When storing your outboard motor for prolonged periods of time 2 months or longer several important procedures must be performed to prevent excessive damage It is advisable to have your out board motor serviced by an authorized Yamaha dealer prior to storage However the following procedures can be per formed by the owner with a minimum of tools cC 8 Do not place the outboard motor on...

Page 69: ...d instead EMU01796 STORING OUTBOARD MOTOR 30 When storing your Yamaha outboard motor for prolonged periods of time 2 months or longer several important pro cedures must be performed to prevent excessive damage This is especially important for your oil injection equipped outboard motor due to the lean oil ratios used at idle prior to shutting the engine off for the season It is advisable to have yo...

Page 70: ...1 Water surface 2 Lowest water level cC If the fresh water level is below the level of the anti cavitation plate or if the water supply is insufficient engine seizure may occur w 8 Do not touch or remove electrical parts when starting or during operation 8 Keep hands hair and clothes away from flywheel and other rotating parts while engine is running 3 Run the engine at a fast idle for 10 15 minut...

Page 71: ...ces sary to manually override the control unit to completely fill the engine main tank Refer to TEMPORARY ACTION IN EMERGENCY 4 Change the lower unit oil Refer to CHANGING GEAR OIL Inspect the oil for the presence of water which indicates a leaky seal Seal replace ment should be performed by an authorized Yamaha dealership prior to use 5 Grease all grease fittings Refer to GREASING EMK27011 Cleani...

Page 72: ...intenance unless otherwise specified If the owner is not familiar with machine servicing this work should be done by a Yamaha dealer or other quali fied mechanic Maintenance replacement or repair of the emission control devices and systems may be performed by any marine engine repair establishment or individual All warranty repairs however including those to the emission control system must be per...

Page 73: ...Cleaning adjustment replacement Greasing points Greasing Gear oil Change Fuel system Inspection Fuel filter can be disassembled Inspection cleaning Fuel tank Yamaha portable tank Inspection cleaning Idling speed carburetor models Inspection adjustment 1 1 Anode s external Inspection replacement 1 1 Anode s internal Inspection replacement 1 Cooling water passages Cleaning Propeller and cotter pin I...

Page 74: ...ir leak or carburetion problem in that cylinder Do not attempt to diagnose any problems yourself Instead take the outboard motor to a Yamaha dealer You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive you should replace the spa...

Page 75: ... to 1 2 a turn past finger tight Have the spark plug adjusted to the correct torque as soon as possible with a torque wrench 1 Spark plug gap 2 Spark plug I D mark NGK Spark plug torque Refer to SPECIFICATIONS page 4 1 Initial of spark Plug wrench size plug I D mark B 21 mm 13 16 in C BK 16 mm 5 8 in D 18 3 mm 23 32 in 903022 q w EMU16350 CHECKING TOP COWLING Check the fitting of the top cowling b...

Page 76: ...d it should be repaired immediately by Yama ha dealer or other qualified mechanic Checking points 8 Fuel system parts leakage 8 Fuel hose joint leakage 8 Fuel hose cracks or other damage 8 Fuel connector leakage w Leaking fuel can result in fire or explo sion 8 Check for fuel leakage regularly 8 If any fuel leakage is found the fuel system must be repaired by a qualified mechanic Improper repairs ...

Page 77: ...embled carefully with O ring filter cup and hoses in place Improper assembly or replacement can result in a fuel leak which could result in a fire or explosion hazard 000983 q w e r EMU09782 1 Remove the nut holding the fuel filter assembly if equipped 2 Unscrew the filter cup 1 catching any spilled fuel in a rag 3 Remove the filter element 2 and wash it in solvent Allow it to dry Inspect the filt...

Page 78: ...r rotating parts while engine is running cC This procedure must be performed while the outboard motor is in the water A flushing attachment or test tank can also be used A diagnostic tachometer should be used for this procedure Results may vary depending on whether testing is conduct ed with the flushing attachment in a test tank or with the outboard motor in the water 1 Start the engine and allow...

Page 79: ...ly the idle speed will measure higher than normal If you have difficulty verifying the idle speed or the idle speed requires adjustment consult a Yamaha dealer or other qualified mechan ic q w EMU03782 CHECKING WATER IN ENGINE OIL TANK A translucent water drain hose is connect ed from the bottom of the oil tank to the filler neck If water or foreign matter col lects in this hose consult a Yamaha d...

Page 80: ... that each connector is engaged securely EXHAUST LEAKAGE Start the engine and check that no exhaust leaks from the joints between the exhaust cover cylinder head and crank case WATER LEAKAGE Start the engine and check that no water leaks from the joints between the exhaust cover cylinder head and crank case ...

Page 81: ...4 16 E MU00366 GREASING Yamaha marine grease Water resistant grease 25 103141b ...

Page 82: ...4 17 E 25 3 30 103141a EMU00366 GREASING Yamaha marine grease Water resistant grease ...

Page 83: ...ne stop switch Turn off the battery cut off switch if your boat has one 8 Do not use your hand to hold the pro peller when loosening or tightening the propeller nut Put a wood block between the cavitation plate and the propeller to prevent the propeller from turning 210012 602052 602051 602054 EMU00390 Propeller Checking Point 8 Check each of the propeller blades for wear erosion from cavitation o...

Page 84: ...aft 3 Install the spacer and washer Tighten the propeller nut to the specified torque 4 Align the propeller nut with the pro peller shaft hole Insert a new cotter pin in the hole and bend the cotter pin ends NOTE If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque then tighten the nut fur ther to align it with the hole EMU00976 Removing the Pr...

Page 85: ...Tilt the outboard motor so that the gear oil drain screw is at the lowest point possible 2 Place a suitable container under the gear case 3 Remove the gear oil drain screw 1 4 Remove the oil level plug 2 to allow the oil to drain completely cC Inspect the used oil after it has been drained If the oil is milky water is get ting into the gear case which can cause gear damage Consult a Yamaha dealer ...

Page 86: ...ML22011 CLEANING FUEL TANK w Gasoline petrol is highly flammable and its vapors are flammable and explosive 8 If you have any question about properly doing this procedure consult your Yamaha dealer 8 Keep away from sparks cigarettes flames or other sources of ignition when cleaning the fuel tank 8 Remove the fuel tank from the boat before cleaning it Work only outdoors in an area with good ventila...

Page 87: ...lvent Allow the filter to dry 3 Replace the gasket with a new one Reinstall the fuel hose joint assembly and tighten the screws firmly EMU14622 INSPECTING AND REPLACING ANODE S Yamaha outboard motors are protected from corrosion by sacrificial anodes Inspect the external anodes periodically Remove scales from the surfaces of the anodes Consult a Yamaha dealer for replacement of external anodes cC ...

Page 88: ...he areas Consult a Yamaha dealer for touch up paint EML44010 COATING THE BOAT BOTTOM A clean hull improves boat performance The boat bottom should be kept as clean of marine growths as possible If neces sary the boat bottom can be coated with an anti fouling paint approved for your area to inhibit marine growth Do not use anti fouling paint which includes copper or graphite These paints can cause ...

Page 89: ...EMN00010 Chapter 5 TROUBLE RECOVERY TROUBLESHOOTING 5 1 TEMPORARY ACTION IN EMERGENCY 5 5 Impact damage 5 5 Starter will not operate 5 6 Treatment of submerged motor 5 8 1 2 3 4 5 6 E ...

Page 90: ...ogged 4 Starting procedure incorrect 5 Fuel pump malfunctions 6 Spark plug s fouled or incorrect type 7 Spark plug cap s fitted incorrectly 8 Poor connections or damaged ignition wiring 9 Ignition parts faulty 10 Engine stop switch lanyard not attached 11 Engine inner parts damaged 1 Fill tank with clean fresh fuel 2 Fill tank with clean fresh fuel 3 Clean or replace filter 4 Read STARTING ENGINE ...

Page 91: ...ncorrect 18 Throttle valve adjustment incorrect 1 Inspect spark plug s Clean or replace with recommended type 2 Check for pinched or kinked fuel line or other obstructions in fuel system 3 Fill tank with clean fresh fuel 4 Clean or replace filter 5 Have serviced by a Yamaha dealer 6 Find and correct cause of warning 7 Inspect and adjust as specified 8 Check wires for wear or breaks Tighten all loo...

Page 92: ...ged 2 Propeller pitch or diameter incorrect 3 Trim angle incorrect 4 Motor mounted at incorrect height on transom 5 Warning system activated 6 Boat bottom fouled with marine growth 7 Spark plug s fouled or incorrect type 8 Weeds or other foreign matter tangled on gear housing 9 Fuel system obstructed 10 Fuel filter clogged 11 Fuel contaminated or stale 12 Spark plug gap incorrect 1 Have propeller ...

Page 93: ...amaha dealer 15 Check and replace oil with specified type 16 Have serviced by a Yamaha dealer 17 Open the air vent screw 18 Have serviced by a Yamaha dealer 19 Connect correctly 20 Inspect spark plug and replace it with recommended type D Engine power loss E Engine vibrates excessively 1 Propeller damaged 2 Propeller shaft damaged 3 Weeds or other foreign matter tangled on propeller 4 Motor mounti...

Page 94: ...ut board motor unsafe to operate If the outboard motor hits any object in the water follow the procedure below 1 Stop the engine immediately 2 Inspect the control system and all components for damage Also inspect the boat for damage 3 Whether damage is found or not return to the nearest harbor slowly and carefully 4 Have a Yamaha dealer inspect the outboard motor before operating it again ...

Page 95: ...t could unexpectedly start to move which could result in an accident 8 Be sure no one is standing behind you when pulling the starter rope It could whip behind you and injure someone 8 An unguarded rotating flywheel is very dangerous Keep loose clothing and other objects away when starting the engine Use the emergency starter rope only as instructed Do not touch the fly wheel or other moving parts...

Page 96: ...the engine is in Neutral and that the lock plate is attached to the engine stop lanyard switch The main switch must be ON if equipped it 5 Pull out the choke knob when a cold engine starts After the engine start return the choke knob 6 Insert the knotted end of the emer gency starter rope into the notch in the flywheel rotor and wind the rope several turns clockwise 7 Give a strong pull straight o...

Page 97: ...horoughly wash away mud salt seaweed etc with fresh water 2 Remove the spark plugs and face the spark plug holes downward to allow any water mud or contaminants to drain 3 Drain the fuel from the carburetor 4 Feed fogging oil or engine oil through the carburetors and spark plug holes while cranking with the manual starter or emergency starter rope 5 Take the outboard motor to a Yamaha dealer as so...

Page 98: ...E MEMO ...

Page 99: ...EMP00010 Chapter 6 INDEX INDEX 6 1 1 2 3 4 5 6 E ...

Page 100: ... button 2 5 Engine stop lanyard switch 2 4 Exhaust leakage 4 16 F Filling fuel 3 5 Filling fuel and engine oil 3 5 Filling fuel tank 4 4 Filling oil 3 6 Flushing cooling system and fogging engine 4 5 Forward 3 19 Fuel hose joint 2 3 Fuel meter 2 3 Fuel tank 2 3 Fuel tank cap 2 3 Fueling instructions 1 10 G Gasoline 1 11 Gasohol 1 11 Gasoline petrol and oil mixing 3 8 Gear shift lever 2 3 Greasing ...

Page 101: ...oring outboard motor 4 3 T Temporary action in emergency 5 5 Throttle control grip 2 5 Throttle friction adjusting screw knob 2 6 Throttle indicator 2 5 Tiller handle 2 5 Tilt lock mechanism 2 9 Tilt support bar 2 10 Tilt support lever 2 10 Tilting up down 3 27 Top cowling lock lever 2 10 Trailering outboard motor 4 2 Transporting and storing outboard motor 4 2 Treatment of submerged motor 5 8 Tri...

Page 102: ...gistration records are checked 2 Read the Limited Warranty statement which follows these instructions This warranty applies to Yamaha outboard motors sold in the United States whether purchased sepa rately or when supplied as original equipment by a boat builder The terms also apply to original equipment packages sold in Canada with coverage provided by Yamaha Motor Canada see Warranty Guide for C...

Page 103: ...ilable in one country may not be sold or serviced in the other 6 If you need any additional information about your Yamaha or warranty coverage which your dealer cannot provide please contact us directly Yamaha Motor Corporation U S A P O Box 6555 Cypress CA 90630 Attention Customer Relations Department Telephone No 714 761 7439 Fax No 714 761 7559 Yamaha Motor Canada Ltd 480 Gordon Baker Road Toro...

Page 104: ...tor purchased and registered for use in the United States only excluding its territo ries For warranty provisions outside the United States contact the particular country s local Yamaha distributor WARRANTY REGISTRATION To be eligible for warranty coverage the outboard motor must first be registered with Yamaha Motor Cor poration U S A A warranty registration form is provided in the Owner s Manual...

Page 105: ...LSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A Post Office Box 6555 Cypress California 90630 WARRANTY QUESTIONS AND ANSWERS Q What costs are my responsibility during the warranty period A The customer s responsibility includes all costs of normal maintenance services non warranty repairs accident and collision dam ages Q What are some examples of abnormal strai...

Page 106: ...ation such as names addresses model engine serial number dates and receipts CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers against the possibility of a safety related defect and recall This list is complied from the purchase registrations sent to Yamaha Motor Corporation U S A by the selling deal...

Page 107: ...ll receive service If you need more information about your warranty coverage or your Yamaha outside the U S A or Canada please contact an autho rized Yamaha dealer in your country 2 Keep a copy of your sales contract or invoice for the purchase of your Yamaha and present it if you need warranty repairs This document should show the date of purchase which is important evidence the repairing dealer ...

Page 108: ...Printed in Japan March 2003 1 0 1 6L2 28199 1K 25NMH E Printed on recycled paper ...

Page 109: ...r au détail OUTBOARD MOTOR MODEL AND SERIAL NUMBER From I D label on clamp bracket MODÉLE ET NO DE SÉRIE DU MOTEUR HORS BORD sur l étiquette d identification de la presse de fixation For Dealer Use Only A l usage du concessionnaire YAMAHA DEALER NUMBER NO DU CONCESSIONNAIRE YAMAHA DEALER NAME NOM DU CONCESSIONNAIRE DATE SOLD DATE DE LIVRAISON OWNER S NAME NOM DU PROPRIÉTAIRE ADDRESS ADRESSE PHONE ...

Page 110: ...PLACE POSTAGE HERE ATTN WARRANTY DEPARTMENT Warranty card 2 27 02 11 47 AM Page 2 ...

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